Experimental Study on High Speed Machining of a Titanium Alloy

2009 ◽  
Vol 69-70 ◽  
pp. 451-455
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Speed ◽  
Fatigue Property ◽  
High Speed Machining ◽  
Ta15 Titanium Alloy ◽  
Milling Tool ◽  
Speed Range

High Speed Machining (HSM) has been proved to be useful in the machining of many materials. This research is concerned with the performance of HSM in the milling of Ti-6.5Al-2Zr-1Mo-1V (TA15) titanium alloy. The tool life and wear mechanism of the milling tool under different cutting speed were investigated, and the influences of cutting speed on the surface integrity and fatigue property of the machined part were studied. According to the experimental results, acceptable tool life can be obtained in a speed range up to 200m/min. The results also show that increasing cutting speed can help to improve the surface integrity and fatigue property of the machined part.

Surface Integrity and Fatigue Property of a High Speed Milled Titanium Alloy

2008 ◽  
Vol 53-54 ◽  
pp. 305-310 ◽  
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Work Hardening ◽  
High Speed ◽  
Cutting Speed ◽  
Fatigue Property ◽  
Machined Surface ◽  
Metallurgical Structure

Surface integrity has a great effect on the fatigue property of titanium alloy. The surface integrity and fatigue property of a high speed milled Ti-6.5Al-2Zr-1Mo-1V (TA15) titanium alloy were investigated in this research. The main objective of this paper is to study the influence of milling speed on the surface integraty and fatigue property of the machined part. The surface roughness, work hardening, metallurgical structure and residual stress of the machined surface were studied in a cutting speed range of from 50m/min to 300m/min. To verify the relationship between cutting speed and the surface integrity of machined surface, the fatigue property of titanium alloy specimens milled at four different cutting speeds ranging from 50 to 200m/min were compared at two stress levels. This research shows that the cutting speed has little effect on the work hardening, metallurgical structure and residual stress, but the surface roughness decreases with the increasing cutting speed. Therefore, increasing milling speed has a positive effect on the surface integrity and fatigue property of the machined surface.

Observations of Tool Life and Wear Mechanisms in High Speed Machining of Ti-6Al-4V With PCD Tools Using High Pressure Coolant Supply

2005 ◽  
Author(s):  
E. O. Ezugwu ◽  
J. Bonney ◽  
W. F. Sales ◽  
R. B. da Silva
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Life ◽  
Wear Mechanisms ◽  
High Speed ◽  
Cutting Tool ◽  
High Speed Machining ◽  
The Past ◽  
Pcd Tools ◽  
High Pressure Coolant

Usage of titanium alloys has increased since the past 50 years despite difficulties encountered during machining. In this study PCD tools were evaluated when machining Ti-6Al-4V alloy at high speed conditions under high pressure coolant supplies. Increase in coolant pressure tend to improve tool life and minimise adhesion of the work material on the cutting tool during machining. Adhesion can be accelerated by the susceptibility of titanium alloy to galling during machining.

The Influences of Cutting Speed on the Fatigue of Titanium Alloy

2007 ◽  
Vol 10-12 ◽  
pp. 742-746
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu
Keyword(s):  
Titanium Alloy ◽  
Electron Microscope ◽  
High Speed ◽  
Cutting Speed ◽  
Cyclic Stress ◽  
Fatigue Properties ◽  
Stress Strain ◽  
Ta15 Titanium Alloy ◽  
Cutting Speeds ◽  
Scanning Electron

This research is concerned with the influences of cutting speed on the fatigue properties of high speed milled Ti-6.5Al-2Zr-1Mo-1V (TA15) titanium alloy. Four different cutting speeds ranging from 50 to 200m/min were used to mill the specimens for fatigue test, and the fatigue properties of them were studied at two stress levels: 80—800MPa and 90—900MPa. The fatigue lives of the specimens milled under different cutting speeds were compared. The fracture surfaces were analyzed using scanning electron microscope (SEM), and cyclic stress-strain properties of TA15 titanium alloy were investigated with a stress-strain gauge. The results showed that increasing cutting speed can help to improve the fatigue properties of titanium alloy, especially at a relatively low cyclic stress level.

Study on Tool Wear of Cutting Ti-6Al-4V with Water Steam as Coolant and Lubricant in Green Machining

2010 ◽  
Vol 97-101 ◽  
pp. 2365-2368
Author(s):  
Yue Zhang ◽  
Rong Di Han ◽  
Tai Li Sun ◽  
Qi Dong Li ◽  
Xi Chuan Zhang
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Small Diameter ◽  
Water Steam ◽  
Green Machining ◽  
Water Based ◽  
Cutting Zone ◽  
Steam Cooling

To achieve green machining of titanium alloy Ti-6Al-4V with water steam cooling and lubricating, a 600-800w minitype generator is developed. Compared to dry and water-based emulsion, the using of water steam improves Ti-6Al-4V machinability and prolongs the tool life about 1 time and 0.5 times. And if the same tool life was selected, it would be easy to obtain that as water steam applied the cutting speed can increase about 15% and 10%. As a result, the productivity can be increased. The excellent cooling and lubricating action of water steam could be summarized that water molecule has a small diameter and high speed, can be easily and rapidly to penetrate the capillaries and proceed adsorption in the cutting zone. The results indicate that the using of water steam has the potential to attain the green machining of titanium alloy Ti-6Al-4V.

Tool Wear and Surface Integrity in High Speed Milling of Forging and Cast TA15 Alloys with Coated Carbide Tools

2009 ◽  
Vol 626-627 ◽  
pp. 189-194
Author(s):  
P. Liu ◽  
Jiu Hua Xu ◽  
Yu Can Fu
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Milling ◽  
Alpha Titanium ◽  
Series Of Experiments ◽  
Coated Carbide ◽  
Coated Carbide Tools

TA15 (Ti-6.5Al-2Zr-1Mo-1V) is a close alpha titanium alloy strengthened by solid solution with Al and other component. A series of experiments were carried out on normal and high speed milling of TA15. The recommended tools for many years had been the uncoated tungsten carbide grade K. In this work, the tool life of coated carbide tools used in high speed milling of forging and cast titanium alloy was studied. Additionally, the wear mechanism of cutting tools was also discussed. Finally, surface integrity, including surface roughness, metallograph and work hardening, were examined and analyzed. The result shows that the surface quality of forging and cast machined by carbide cutter is similar, but the tool life of carbide in high speed milling of forging TA15 is longer than that in high speed milling of cast TA15.

Air Jet Assisted Machining of Inconel 718 with Whisker Reinforced Ceramic Tool

2013 ◽  
Vol 554-557 ◽  
pp. 2079-2084 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Kazuhiro Funai
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Chemical Properties ◽  
High Speed Machining ◽  
Ceramic Tool ◽  
Air Jet ◽  
Hot Machining ◽  
Notch Wear

Nickel alloy is widely applied to aero-engines, marine structures, chemical plants, etc. This alloy has superior mechanical and chemical properties, but is one of difficult-to-machine materials because of its superior properties. For this reason, various machining methods, such as cryogenic machining, hot machining, machining using high pressure coolant and rotary machining have been studied for increasing the cutting speed and cutting efficiency of this alloy. Recently, a new lubrication method called air jet assisted (AJA) machining was developed to extend tool life by 20-30% in finish-turning of Inconel 718 and Ti-6Al-4V. In this machining method air jet as well as coolant was applied to the cutting area. In this study, AJA machining was applied to high speed machining of Inconel 718 with a SiC whisker reinforced ceramic tool. The air jet was applied from an air nozzle at the tool flank face. Because the ceramic tool is likely to suffer from severe notch wear, the influence of AJA machining on flank and notch wear of the ceramic tool was investigated experimentally. As a result, it was found that as compared to conventional wet machining, AJA machining increased flank wear but reduced notch wear, which is usually critical to the tool life of the reinforced ceramic tool. The tool wear characteristics peculiar to AJA machining were effective for extending tool life in high speed machining of this alloy.

scholarly journals A New Cutting Tool Design for Cryogenic Machining of Ti–6Al–4V Titanium Alloy

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 477 ◽  
Author(s):  
Alborz Shokrani ◽  
Stephen Newman
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Tool Life ◽  
Material Removal Rate ◽  
Surface Integrity ◽  
Material Removal ◽  
Cutting Tool ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cryogenic Machining

Titanium alloys are extensively used in aerospace and medical industries. About 15% of modern civil aircrafts are made from titanium alloys. Ti–6Al–4V, the most used titanium alloy, is widely considered a difficult-to-machine material due to short tool life, poor surface integrity, and low productivity during machining. Cryogenic machining using liquid nitrogen (LN2) has shown promising advantages in increasing tool life and material removal rate whilst improving surface integrity. However, to date, there is no study on cutting tool geometry and its performance relationship in cryogenic machining. This paper presents the first investigation on various cutting tool geometries for cryogenic end milling of Ti–6Al–4V alloy. The investigations revealed that a 14° rake angle and a 10° primary clearance angle are the most suitable geometries for cryogenic machining. The effect of cutting speed on tool life was also studied. The analysis indicated that 110 m/min cutting speed yields the longest tool life of 91 min whilst allowing for up to 83% increased productivity when machining Ti–6Al–4V. Overall the research shows significant impact in machining performance of Ti–6Al–4V with much higher material removal rate.

Study on High Speed Milling of Steam Turbine Blade Materials

2016 ◽  
Vol 1136 ◽  
pp. 251-256
Author(s):  
Tomonori Kimura ◽  
Takekazu Sawa ◽  
Tatsuyuki Kamijyo
Keyword(s):  
Stainless Steel ◽  
Titanium Alloy ◽  
Steam Turbine ◽  
Turbine Blade ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Milling ◽  
Steam Turbine Blade ◽  
Cutting Point

A titanium alloy and stainless steel is an excellent material having properties such as high intensity and high corrosion resistance. Therefore, a titanium alloy and a stainless steel are used as material of steam turbine blade. However, the machining efficiency of a titanium alloy and a stainless steel is a low because of difficult-to-cut materials. Especially, it is a major problem that the cutting point temperature is high and the tool life is short. In the conventional study, it is reported that the cutting point temperature is low and the tool life becomes long by cutting at the suitable cutting speed corresponding to material characteristics. This concept is known as high speed milling. In recent years, the high speed milling is actually used for the metal mold machining. In this study, the high speed milling of the titanium alloy and the stainless steel was tried for the purpose of high efficiency cutting of a steam turbine blade. In the experiment, the cutting tool used the TiAlN coating radius solid end mill made of micro grain cemented carbide. The diameter of endmill is 5mm. The corner radius is 0.2mm. And, the work piece is the titanium alloy Ti-6Al-4V and stainless steel 13Cr. The cutting speed carried out at 100m/min~600m/min. As the result, when the tool life and the surface roughness was a valuation basis, the optimum cutting speed of titanium alloy was 300m/min. On the other hand, In the case of the stainless steel, the flank wear becomes large in proportion to cutting speed. The feature of high speed milling was not able to be confirmed in the range of this experimental condition.

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