Laser Assisted Machining of Ti10V2Fe3Al and Ti6Cr5Mo5V4Al β Titanium Alloys

2014 ◽  
Vol 974 ◽  
pp. 121-125 ◽  
Author(s):  
R.A. Rahman Rashid ◽  
S. Sun ◽  
Suresh Palanisamy ◽  
M.S. Dargusch
Keyword(s):  
Titanium Alloys ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Laser Assisted Machining ◽  
Machining Conditions ◽  
Titanium Machining ◽  
Research Activities

In recent times, the market for the applications of titanium alloys, particularly β alloys, is growing rapidly, calling for higher productivity. However, it is difficult to machine titanium alloys. A number of research activities have been carried out in this area to improve the productivity of titanium machining. Laser assisted machining is one technique which has been proposed to enhance the machinability of various difficult-to-cut materials including titanium alloys. In this study, two β titanium alloys, viz. Ti-10V-2Fe-3Al and Ti-6Cr-5Mo-5V-4Al, were machined using laser assistance and the results were compared with unassisted machining conditions. Their response to laser assisted machining in terms of differences in the cutting forces, cutting temperature and chip formation are reported. It was found that the Ti-6Cr-5Mo-5V-4Al workpiece was much more difficult to machine even with laser assistance.

Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method

2011 ◽  
Author(s):  
Xiangqin Zhang ◽  
Xueping Zhang ◽  
A. K. Srivastava
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Process ◽  
Fe Model ◽  
Dry Cutting ◽  
Friction Coefficients ◽  
Machining Conditions

To predict the cutting forces and cutting temperatures accurately in high speed dry cutting Ti-6Al-4V alloy, a Finite Element (FE) model is established based on ABAQUS. The tool-chip-work friction coefficients are calculated analytically using the measured cutting forces and chip morphology parameter obtained by conducting the orthogonal (2-D) machining tests. It reveals that the friction coefficients between tool-work are 3∼7 times larger than that between tool-chip, and the friction coefficients of tool-chip-work vary with feed rates. The analysis provides a better reference for the tool-work-chip friction coefficients than that given by literature empirically regardless of machining conditions. The FE model is capable of effectively simulating the high speed dry cutting process of Ti-6Al-4V alloy based on the modified Johnson-Cook model and tool-work-chip friction coefficients obtained analytically. The FE model is further validated in terms of predicted forces and the chip morphology. The predicted cutting force, thrust force and resultant force by the FE model agree well with the experimentally measured forces. The errors in terms of the predicted average value of chip pitch and the distance between chip valley and chip peak are smaller. The FE model further predicts the cutting temperature and residual stresses during high speed dry cutting of Ti-6Al-4V alloy. The maximum tool temperatures exist along the round tool edge, and the residual stress profiles along the machined surface are hook-shaped regardless of machining conditions.

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

2016 ◽  
Vol 36 (1) ◽  
pp. 12-17 ◽  
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.

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

2017 ◽  
Vol 1142 ◽  
pp. 250-253
Author(s):  
Ze WU ◽  
You Qiang Xing ◽  
Peng Huang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloys ◽  
Fiber Laser ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Face Milling ◽  
Laser Machining ◽  
Dry Milling ◽  
Temperature Surface

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.

The effects of cryogenic cooling on chips and cutting forces in turning AISI 1040 and AISI 4320 steels

2002 ◽  
Vol 216 (5) ◽  
pp. 713-724 ◽  
Author(s):  
N R Dhar ◽  
Nanda S V Kishore ◽  
S Paul ◽  
A B Chattopadhyay
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Substantial Reduction ◽  
Cutting Temperature ◽  
Environmentally Friendly ◽  
Cryogenic Cooling ◽  
Experimental Investigations ◽  
High Production ◽  
On Chip

Application of conventional cutting fluids often cannot control the high cutting temperatures, especially in high production machining. In addition, they are a major source of pollution in machining industries. Cryogenic cooling is a potential environmentally friendly clean technology for desirable control of the cutting temperature. The present work deals with experimental investigations on the role of cryogenic cooling by liquid nitrogen jets on chip formation and cutting forces in turning AISI 1040 steel and AISI 4320 steel at industrial speed—feed combinations by two types of carbide inserts of different geometrical configurations. The experimental results indicate the possibility of a substantial reduction in cutting forces by cryogenic cooling, which enabled a reduction in cutting forces by favourable chip formation, chip—tool interaction and also retention of tool sharpness due to reduced cutting temperature. Thus cryogenic cooling, if properly employed, is not only environmentally friendly but can also improve machinability characteristics.

Research Status of Subsequent Machining of Laser Cladding Layers

2020 ◽  
Vol 15 ◽  
Author(s):  
Lei Li ◽  
Yujun Cai ◽  
Guohe Li ◽  
Meng Liu
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Laser Cladding ◽  
Wear Surface ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Cladding Layer ◽  
Cladding Layers

Background: As an important method of remanufacturing, laser cladding can be used to obtain the parts with specific shapes by stacking materials layer by layer. The formation mechanism of laser cladding determines the “Staircase effect”, which makes the surface quality can hardly meet the dimensional accuracy of the parts. Therefore, the subsequent machining must be performed to improve the dimensional accuracy and surface quality of cladding parts. Methods: In this paper, chip formation, cutting force, cutting temperature, tool wear, surface quality, and optimization of cutting parameters in the subsequent cutting of laser cladding layer are analyzed. Scholars have expounded and studied these five aspects but the cutting mechanism of laser cladding need further research. Results: The characteristics of cladding layer are similar to that of difficult to machine materials, and the change of parameters has a significant impact on the cutting performance. Conclusion: The research status of subsequent machining of cladding layers is summarized, mainly from the aspects of chip formation, cutting force, cutting temperature, tool wear, surface quality, and cutting parameters optimization. Besides, the existing problems and further developments of subsequent machining of cladding layers are pointed out. The efforts are helpful to promote the development and application of laser cladding remanufacturing technology.

RESEARCH ON CUTTING FORCES AND CUTTING TEMPERATURE IN ORTHOGONAL CUTTING SOFTWOOD AND HARDWOOD PARALLEL TO GRAIN

2018 ◽  
Vol 50 (4) ◽  
pp. 458-464
Author(s):  
Xu Bao ◽  
Xiaolei Guo ◽  
Pingxiang Cao ◽  
Linlin Xie ◽  
Minsi Deng
Keyword(s):  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Temperature

scholarly journals Investigation of the Wear Behavior of PVD Coated Carbide Tools during Ti6Al4V Machining with Intensive Built Up Edge Formation

Coatings ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 266
Author(s):  
M.S.I. Chowdhury ◽  
B. Bose ◽  
S. Rawal ◽  
G.S. Fox-Rabinovich ◽  
S.C. Veldhuis
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Wear Behavior ◽  
Cutting Temperature ◽  
Ti6al4v Alloy ◽  
Adhesive Interaction ◽  
Heavy Load ◽  
Micromechanical Properties ◽  
Rough Turning ◽  
Coated Carbide

Tool wear phenomena during the machining of titanium alloys are very complex. Severe adhesive interaction at the tool chip interface, especially at low cutting speeds, leads to intensive Built Up Edge (BUE) formation. Additionally, a high cutting temperature causes rapid wear in the carbide inserts due to the low thermal conductivity of titanium alloys. The current research studies the effect of AlTiN and CrN PVD coatings deposited on cutting tools during the rough turning of a Ti6Al4V alloy with severe BUE formation. Tool wear characteristics were evaluated in detail using a Scanning Electron Microscope (SEM) and volumetric wear measurements. Chip morphology analysis was conducted to assess the in situ tribological performance of the coatings. A high temperature–heavy load tribometer that mimics machining conditions was used to analyze the frictional behavior of the coatings. The micromechanical properties of the coatings were also investigated to gain a better understanding of the coating performance. It was demonstrated that the CrN coating possess unique micromechanical properties and tribological adaptive characteristics that minimize BUE formation and significantly improve tool performance during the machining of the Ti6Al4V alloy.

scholarly journals Towards Dry Machining of Titanium-Based Alloys: A New Approach Using an Oxygen-Free Environment

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1161
Author(s):  
Hans Jürgen Maier ◽  
Sebastian Herbst ◽  
Berend Denkena ◽  
Marc-André Dittrich ◽  
Florian Schaper ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Wear Mechanism ◽  
Chip Formation ◽  
Cutting Forces ◽  
High Vacuum ◽  
Argon Atmosphere ◽  
Dry Machining ◽  
New Approach ◽  
Underlying Mechanisms ◽  
Free Environment

In the current study, the potential of dry machining of the titanium alloy Ti-6Al-4V with uncoated tungsten carbide solid endmills was explored. It is demonstrated that tribo-oxidation is the dominant wear mechanism, which can be suppressed by milling in an extreme high vacuum adequate (XHV) environment. The latter was realized by using a silane-doped argon atmosphere. In the XHV environment, titanium adhesion on the tool was substantially less pronounced as compared to reference machining experiments conducted in air. This goes hand in hand with lower cutting forces in the XHV environment and corresponding changes in chip formation. The underlying mechanisms and the ramifications with respect to application of this approach to dry machining of other metals are discussed.

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