Predictive Tool Life Model in Ti6Al4V High Speed Milling and Cutting Parameter Optimization

2010 ◽  
Vol 431-432 ◽  
pp. 257-260
Author(s):  
Xiao Qin Wang ◽  
Xing Ai ◽  
Jun Zhao
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Contour Analysis ◽  
Cutting Efficiency ◽  
Predictive Tool ◽  
Life Model ◽  
Cutting Parameter Optimization ◽  
Carbide Insert

Ti6Al4V is a difficult to machine alloy with low cutting efficiency and server tool wear. A series of orthogonal milling tests with coated and uncoated carbide insert was carried out. The tool life predictive models based on orthogonal experiment were developed. Finally, the cutting parameters for both tools in Ti6Al4V dry milling were optimized based on tool life-efficiency contour analysis.

Predictive Tool Life Model of CBN in Ti6Al4V High Speed Turning and Cutting Parameter Optimization

2009 ◽  
Vol 407-408 ◽  
pp. 594-598
Author(s):  
Xiao Qin Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Pei Quan Guo
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Efficiency ◽  
Predictive Tool ◽  
Cbn Tool ◽  
Small Depth ◽  
Cutting Parameter Optimization

Ti6Al4V is a difficult to machine alloy with low cutting efficiency and server tool wear. A series of orthogonal turning tests with CBN (Cubic Boron Nitride) in higher speed scale was carried out on a CA6140 lathe. The experiential functions of tool life based on orthogonal experiment were developed. The tool wear morphologies were examined by scanning electron microscope (SEM) and energy disperse spectroscopy (EDS), adhesion, diffusion and micro-chipping were the major wear mechanisms of CBN tool. Finally, the cutting parameters of CBN tool in Ti6Al4V dry turning were optimized based on tool life-efficiency contour analysis, in same cutting efficiency, the higher cutting speed and small depth of cut are the better selection, it means that utilization of CBN tool enables the high cutting speed turning of Ti6Al4V.

Tool Life Prediction and Cutting Parameter Optimization for Coated Carbide in Ti6Al4V Turning

2012 ◽  
Vol 426 ◽  
pp. 186-189
Author(s):  
X.Q Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
X.L. Fu ◽  
Y. Z. Pan
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Contour Analysis ◽  
Cutting Efficiency ◽  
Coated Carbide Tool ◽  
Cutting Parameter Optimization ◽  
Coated Carbide

Ti6Al4V is a difficult to machine alloy with low cutting efficiency and server tool wear. A series of orthogonal turning tests with coated carbide in higher speed scale was carried out on a CA6140 lathe. The experiential functions of tool life based on orthogonal experiment were developed. The tool wear morphologies were examined by scanning electron microscope (SEM) and energy disperse spectroscopy (EDS), adhesion, diffusion and micro-chipping were the major wear mechanisms of coated carbide tool. Finally, the cutting parameters of coated carbide tool in Ti6Al4V dry turning were optimized based on tool life-efficiency contour analysis, in same cutting efficiency, the lower cutting speed and larger depth of cut are the better selection in Ti6Al4V turning for coated carbide tool.

High Speed Machining of Difficult-to-Machine Materials under Different Lubrication Conditions

2014 ◽  
Vol 625 ◽  
pp. 60-65 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Tatsumi Ohno ◽  
Ryuta Nakatsukasa ◽  
Mamoru Hayashi ◽  
Tomohiko Tabata
Keyword(s):  
Stainless Steel ◽  
Titanium Alloy ◽  
Tool Life ◽  
High Speed ◽  
Life Extension ◽  
Air Jet ◽  
Flank Face ◽  
Air Nozzle ◽  
Carbide Insert ◽  
Lubrication Conditions

This paper describes the applicability of air jet assisted (AJA) machining to stainless steel and titanium alloy at high cutting speeds in terms of tool wear and tool life. A specially designed tool holder with an air nozzle very close to the tool tip was prepared for turning stainless steel. From the experimental results, it was found that the application of flood coolant from the side of the end flank face leads to better result in tool life in AJA machining of stainless steel than that from the side of the side flank face. The assistance of air jet can improve the tool life of the M35 CVD coated insert in machining of the stainless steel by 36 to 100% under the optimal conditions in comparison with wet machining. It was also found that the air jet assistance extended the tool life of the S10 PVD coated insert by 48% in turning titanium alloy. The tool life extension of the coated insert in AJA machining titanium alloy is much longer than that of an uncoated carbide insert.

Design and Experimental Study of a Vespiary Exsector

2012 ◽  
Vol 468-471 ◽  
pp. 397-400
Author(s):  
Yan Hai Tang ◽  
Jin Bing Hu ◽  
Ling Yang ◽  
Pei Xiang He
Keyword(s):  
High Speed ◽  
Orthogonal Experiment ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Small Scale ◽  
Feed Speed ◽  
Revolution Speed ◽  
Significance Levels ◽  
Sealing Mechanism ◽  
Low Efficiency

The traditional removal method of a vespiary is labor-costing with characteristics of low efficiency and safety. According to the work high above the ground with hidden risk of the vespiary removal, a mechanical vespiary exsector was designed. The exsector is driven by a high speed motor, and the vespiary is removed by a cutting wire with high revolution speed. The cutting part can rotate 90 through drawing a pulling rope. A 2-layer sealing mechanism is operated through another pulling rope. The vespiary exsector has overall characteristics of small scale, light weight and good dexterity. Orthogonal experiment results show that factors of cutting speed and feed speed significantly contribute the width of cutting slot at the significance levels of 0.01 and 0.05 respectively, and the optimum cutting parameters are: cutting speed 10000rpm, feed speed 0.04m/s and diameter of the cutting wire 2mm.

scholarly journals Development of generalized tool life model for constant and variable speed turning

2021 ◽  
Author(s):  
Paolo Albertelli ◽  
Valerio Mussi ◽  
Michele Monno
Keyword(s):  
Tool Life ◽  
Cutting Parameters ◽  
Variable Speed ◽  
Additional Tool ◽  
Spindle Speed Variation ◽  
Chatter Vibrations ◽  
Life Model ◽  
Time In Literature ◽  
Life Tests ◽  
First Time

AbstractIn this research, a generalized tool life modelling for considering non-stationary cutting conditions was developed . In particular, for the first time in literature, the model was conceived for predicting the life of the tool when spindle speed variation SSV, one of the most effective techniques for suppressing regenerative chatter vibrations, is used. The proposed formulation takes into account the main cutting parameters and the parameters associated to the SSV. A dedicated experimental campaign of turning tests was executed and the data were used for modelling purposes. The model validation was carried out performing additional tool life tests. According to the analyzed technological scenario, it was found that the generalized formulation can be used for predicting the tool life both at constant spindle machining CSM and adopting SSV with the maximum estimating error of 6%.

Research on Machined Surface Quality for High Speed Turning Titanium Alloy Membrane Discs and Optimization of Cutting Parameters

2010 ◽  
Vol 33 ◽  
pp. 246-250
Author(s):  
Wei Zhang ◽  
Min Li Zheng ◽  
Ming Ming Cheng ◽  
Wen Yong Shi
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Empirical Model ◽  
High Speed ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Cutting Parameter ◽  
High Speed Turning ◽  
Machined Surface Roughness ◽  
Cutting Parameter Optimization

By high speed turning experiment of aerospace engine titanium alloy membrane discs, it researches cutting parameters influence on machined surface roughness of titanium alloy membrane discs, meanwhile measures and analyzes machined surface topography. Machined surface roughness multi-linear regression empirical model of high speed end-surface turning titanium alloy membrane discs is established. Using cutting parameter combination obtained from cutting parameter optimization makes process verification experiment of high speed turning titanium alloy membrane discs. The results show that the established machined surface roughness empirical model of high speed turning titanium alloy membrane discs is credible in statistics, and the process verifying experiment effect is good by using optimized cutting parameters.

scholarly journals Tool Life Modelling In Continuous Variable Speed Turning

2021 ◽  
Author(s):  
Paolo Albertelli ◽  
Valerio Mussi ◽  
Michele Monno
Keyword(s):  
Tool Life ◽  
Cutting Parameters ◽  
Continuous Variable ◽  
Variable Speed ◽  
Additional Tool ◽  
Experimental Campaign ◽  
Spindle Speed Variation ◽  
Chatter Vibrations ◽  
Life Model ◽  
Life Tests

Abstract In this paper, a generalized tool life model that considers nonstationary cutting was developed. In particular, the model was conceived for predicting the life of the tool when Spindle Speed Variation SSV , one of the most effective techniques for suppressing regenerative chatter vibrations, is used. The proposed formulation takes into account the main cutting parameters and the parameters associated to the SSV . A dedicated experimental campaign of turning tests was carried out and the data were used to develop the model. A proper validation was even carried out performing additional tool life tests. It was found that the generalized formulation can be used for predicting the tool life both at constant spindle machining CSM and adopting SSV within the maximum estimating error of 6%.

scholarly journals Estimation of tool life and cutting burr in high speed milling of the compacted graphite iron by DE based adaptive neuro-fuzzy inference system

2019 ◽  
Vol 10 (1) ◽  
pp. 243-254 ◽  
Author(s):  
Longhua Xu ◽  
Chuanzhen Huang ◽  
Rui Su ◽  
Hongtao Zhu ◽  
Hanlian Liu ◽  
...  
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
High Speed ◽  
Fuzzy Inference ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Compacted Graphite Iron ◽  
Inference System ◽  
Compacted Graphite ◽  
Neuro Fuzzy

Abstract. The studies of tool life and formation of cutting burrs in roughing machining field are core issues in high speed milling of compacted graphite iron (CGI). Changing any one of the cutting parameters like cutting speed or feed rate can result in varied tool life and different height of the cutting burrs. In this work in order to study the relationship between cutting parameters and tool life and height of the cutting burrs, a new differential evolution algorithm based on adaptive neuro fuzzy inference system (DE-ANFIS) as a multi-input and multi-output (MIMO) prediction model is introduced to estimate the tool life and height of the cutting burrs. In this model, the inputs are cutting speed, feed rate and exit angle, and the outputs are tool life and height of the cutting burrs. There are 12 fuzzy rules in DE-ANFIS architecture. Gaussian membership function is adopted during the training process of the DE-ANFIS. The proposed DE-ANFIS model has been compared with PSO-ANFIS, Artificial Neural Network (ANN) and Support Vector Machines (SVM) models. To construct the predictive models, 25 cutting data were obtained through the experiments. Compared with PSO-ANFIS, ANN and SVM models, the results indicate that DE-ANFIS can provide a better prediction accuracy of tool life and height of the cutting burrs, and achieve the required product and productivity. Finally, the analysis of variance (ANOVA) shows that the cutting speed and feed rate have the most effects on the tool life and height of cutting burrs, respectively.

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.

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