Tool Wear Performance of CVD-Insert during Machining of Ti-6%Al-4%V ELI at High Cutting Speed

2010 ◽  
Vol 443 ◽  
pp. 371-375 ◽  
Author(s):  
Gusri Akhyar Ibrahim ◽  
Che Hassan Che Haron ◽  
Jaharah Abd. Ghani
Keyword(s):  
Titanium Alloys ◽  
Cutting Tool ◽  
Chemical Reactivity ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
High Cutting Speed ◽  
Aerospace Material ◽  
Coating Delamination

Machining of titanium alloys as aerospace material that has extremely strength to weight ratio and resistant to corrosion at high-elevated temperature, become more interested topic. However, titanium alloys have low thermal conductivity, relative low modulus elasticity and high chemical reactivity with many cutting tool materials. The turning parameters evaluated are cutting speed (55, 75, 95 m/min), feed rate (0.15, 0.25, 0.35 mm/rev), depth of cut (0.10, 0.15, 0.20 mm) and tool grade of CVD carbide tool. The results that pattern of tool life progression is rapidly increase at the initial stage. It was due to small contact area between the cutting tool and the workpiece. At the first step of machining, the chip welded at the cutting edge but some chip removed away from the cutting edge. Wear mechanism produced are abrasive wear, adhesive, flaking, chipping at the cutting edge and coating delamination.

Tool Wear Mechanism in Continuous Cutting of Difficult-to-Cut Material under Dry Machining

2010 ◽  
Vol 126-128 ◽  
pp. 195-201 ◽  
Author(s):  
Gusri Akhyar Ibrahim ◽  
Che Hassan Che Haron ◽  
Jaharah A. Ghani
Keyword(s):  
Abrasive Wear ◽  
Wear Mechanism ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Nose Radius ◽  
High Cutting Speed ◽  
Coating Delamination ◽  
High Depth

Wear mechanism on the flank of a cutting tool is caused by friction between newly machined surface and the cutting tool, which plays predominant role in determining tool life. Detailed study on wear mechanism at the cutting edge of carbide tools were carried out at cutting speed of 55 – 95 m/min, feed rate of 0.15 – 0.35 mm/rev and depth of cut of 0.10 – 0.20 mm. The wear on the cutting tools was occurred predominantly on the nose radius, as effect of lower feedrate and nose radius selected. Various wear observed on both coated and uncoated cutting tool such as abrasive wear, adhesive wear, adhering chip on the cutting edge, flaking, chipping, coating delamination of coated tool, crack and fracture. The abrasive wear predominantly occurred on the flank face while the flaking on the rake face. Abrasive wear occurred at nose radius due to the depth of cut selected was low therefore, the contact area between the cutting tool and the workpiece material was small. Adhesion or welded titanium alloy onto the flank and rake faces demonstrated a strong bond at the workpiece-tool interface. The adhesion wear takes place after the coating has worn out or coating delamination has been occurred. The crack occurred possibly due to machining at high cutting speed and high depth of cut. Cutting at high cutting speed caused more heat generated at the cutting edge and at high depth of cut caused more cutting forces on the insert.

Study of Nanolayer AlTiN/TiN Coating Deposition on Cemented Carbide and its Performance as a Cutting Tool

2017 ◽  
Vol 47 ◽  
pp. 1-10 ◽  
Author(s):  
Halil Caliskan ◽  
Emre Altas ◽  
Peter Panjan
Keyword(s):  
Surface Roughness ◽  
Wear Resistance ◽  
Elevated Temperatures ◽  
Chemical Reactivity ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Tin Coating ◽  
Coated Tools

Titanium and its alloys are widely used in aerospace and aviation industries because of their high strength-to-weight ratio, high fracture resistance and corrosion resistance at elevated temperatures. However, chemical reactivity and low thermal conductivity of these alloys lead to adhesion and diffusion wears on carbide tools, respectively. In addition, fluctuations in cutting forces occur during the cutting process due to chip shear band formation; and chipping wear is observed at the tool cutting edge as a result. Therefore, machining of these alloys is a challenge for researchers. A common method to increase the lifetime of carbide tools is to coat them with a thin hard coating. In this study, a nanolayer AlTiN/TiN coating was deposited on carbide cutting tools using an industrial magnetron sputtering system in order to enhance their wear resistance and lifetime in milling of Ti6Al4V. The cutting tests with the coated tools were performed at a cutting speed of 50 m/min, feed rate of 0.1 mm/tooth and depth of cut of 1 mm under dry conditions. Tool wear and surface roughness on the workpiece were measured and recorded as a function of cutting distance. Wear mechanisms and types were revealed using optical and scanning electron microscopy and energy dispersive spectroscopy. It was found that the nanolayer AlTiN/TiN coated tools provide higher wear resistance and 4 times longer lifetime when compared to uncoated ones. The main observed wear types are notch wear and build-up edge formation on the cutting edge. A slight improvement in surface roughness of the workpiece was observed with the nanolayered coating.

Fuzzy Modeling of Surface Roughness Parameters in Machining Ti-6Al-4V Alloy

2015 ◽  
Vol 766-767 ◽  
pp. 681-686 ◽  
Author(s):  
J. Nithyanandam ◽  
K. Palanikumar ◽  
Sushil Laldas
Keyword(s):  
Surface Roughness ◽  
Titanium Alloys ◽  
Chemical Reactivity ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Fuzzy Modeling ◽  
Depth Of Cut ◽  
Work Piece ◽  
Nose Radius

Titanium alloys are attractive materials used in different engineering applications, due to its excellent combination of properties such as high strength to weight ratio, good corrosion resistance and high temperature applicability. They are also being used increasingly in chemical process, automotive, biomedical and nuclear plant. When machining of Titanium alloys with traditional tools the tool wear rate high. Because of high chemical reactivity and low modulus of elasticity resulting high cutting temperature and strong adhesion between the tool and work piece materials. The poly crystalline diamond (PCD) cutting tool is used for the turning experiment. The turning parameters for the experimental work are cutting speed, feed, nose radius, and depth of cut. From the results, analysis of the influences of the individual parameters on the surface roughness have been carried out. Fuzzy modeling technique is effectively used to predict the surface roughness in the machining of titanium alloy.

Improvement of Surface Roughness in End Milling of Ti6Al4V by Coupling RSM with Genetic Algorithm

2011 ◽  
Vol 264-265 ◽  
pp. 1154-1159
Author(s):  
Anayet Ullah Patwari ◽  
A.K.M. Nurul Amin ◽  
S. Alam
Keyword(s):  
Genetic Algorithm ◽  
Surface Roughness ◽  
Titanium Alloys ◽  
End Milling ◽  
Fitness Function ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Resistance Surface

Titanium alloys are being widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. Surface roughness is one of the most important requirements in machining of Titanium alloys. This paper describes mathematically the effect of cutting parameters on Surface roughness in end milling of Ti6Al4V. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated. The developed RSM is coupled as a fitness function with genetic algorithm to predict the optimum cutting conditions leading to the least surface roughness value. MATLAB 7.0 toolbox for GA is used to develop GA program. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to achieve the minimum surface roughness value.

Performance of Brazed Carbide End Mill Tool for Machining of Ti6Al4V

2014 ◽  
Vol 541-542 ◽  
pp. 363-367 ◽  
Author(s):  
Saad Nawaz ◽  
Li Xiao Xing ◽  
Zhou Chai
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Thermal Stresses ◽  
Elevated Temperatures ◽  
Aerospace Industry ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Depth Of Cut ◽  
End Mill

Titanium alloys are attractive materials for aerospace industry due to their exceptional strength to weight ratio that is maintained at elevated temperatures and their good corrosion resistance. Major applications of Titanium alloys were military aerospace industry, but since last decade the trend has now shifted towards commercial industry. On the other hand Titanium alloys are notorious for being poor thermal conductor that leads to them being difficult materials for machining. In this experimental study brazed carbide end mill of grade 5 is used for rough down milling of Ti6Al4V for large depth of cut under different combinations of parameters and application of high pressure coolant. The machining performance was evaluated in terms of tool wear, tool life, thermal crack and tool breaking. The tool wear was mostly observed at the tool tip and at bottom part of tool thermal cracks were observed which propagated with respect to time. Flank wear due to scratching of the cutting chips and diffusion wear because of high thermal stresses were observed specially at the bottom of the cutting tool. At cutting speed of 38m/min tool wear couldnt be observed due to tool failure because of fracture under high thermal stresses. It was found that maximum tool life is obtained at the speed of 25m/min, feed rate of 150mm/min and depth of cut of 10mm. In the end it was concluded that machining of Ti6Al4V is a thermally dominant process which leads to high thermal stresses in machining zone that results in increasing tool wear rate and fracture propagation.

Study The Effect of Cutting Conditions (Cutting Speed, Depth of Cut, Feed ) on The Wear of Cutting Tool Bit Turning Machine

2013 ◽  
Vol 1 (2) ◽  
pp. 44-55
Author(s):  
Niema H Elmosawi ◽  
Shalan Gannam Al ◽  
Hamid H. Ali
Keyword(s):  
High Temperature ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Wear Test ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Test Results

The aim of the work is to study the effect of cutting condition on cutting bit of the turning machine while working on different metal ,Through using a special type of commonly used cutting tool bit in (HSS) due to the high qualifications it is characterized by cutting ,and its endurance of high temperature .Two types of metal are used in cutting (Aluminum, Mild steel),relying on the working conditions used in the machine(feed, cutting speed، depth of cut),while conducting working processes via using cooling liquid ,and without it .The wear test results shown that there are two types of wear measured by the (tool micker microscope) :Flank wear and Greater wear, are formed on the cutting edge of the tool bits as a result of the great effect of cutting conditions on the tool bit and the high temperature of the chips ;in addition to the occurrence of resulting edge on the cutting edge of the tool bits in the process of cutting aluminum , with the use of cooling liquids which prolong the of cutting tool and decrease the periods of re-grinding the cutting tool bit. 

Numerical Analysis of Tool Performance in Up Milling of Ti-6Al-4V Alloy

2014 ◽  
Author(s):  
J. Ma ◽  
Patrick Andrus ◽  
Nick H. Duong ◽  
Marissa Fischer ◽  
Sridhar Condoor ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Temperature Distribution ◽  
Elevated Temperatures ◽  
Chemical Reactivity ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Biological Properties ◽  
Heat Transfer Process ◽  
Depth Of Cut ◽  
Transfer Model

Ti-6Al-4V is widely used in industry because of its high strength-to-weight ratio at elevated temperatures, its excellent resistance to fracture and corrosion, and biological properties. However, Ti-6Al-4V is classified as hard-to-cut material because of its high chemical reactivity with most tool materials and its low thermal conductivity that causes high temperature on the tool face. Consequently, prediction of the tool temperature distribution has great significance in predicting tool wear pattern. In this research, Finite Element Method (FEM) is employed to conduct numerical investigation of the effects of cutting conditions (cutting speed, feed/tooth, and axial depth of cut) in corner up milling on temperature of the tool rake face. The tool material used is general carbide and the behavior of the workpiece Ti-6Al-4V is described by using Johnson-Cook plastic model. Because of the computational expense, a separate heat transfer model is built to analyze the heat transfer process after the tooth disengages the workpiece and before it engages the workpiece again to predict change of temperature distribution during this cooling process. This research provides helpful guidance for selecting tool cooling strategies in up milling Ti-6Al-4V alloy.

scholarly journals Experimental Investigation on Machinability of Titanium Alloy by Laser-Assisted End Milling

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1552
Author(s):  
Dong-Hyeon Kim ◽  
Choon-Man Lee
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Titanium Alloy ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Cutting Tool ◽  
End Milling ◽  
Chemical Reactivity ◽  
Depth Of Cut ◽  
Laser Assisted Machining

The Machining of titanium alloys is challenging because of their high strength, low thermal conductivity, high chemical reactivity, and high stresses at the cutting tool edges. Laser-assisted machining is an effective way to improve the machinability of titanium alloys. This paper presents an experimental investigation of the machinability of cutting force and surface roughness in laser-assisted end milling of titanium alloy Ti-6Al-4V. The absorptivity of Ti-6Al-4V was determined by conducting preheating experiments using a high-power diode laser with a wavelength of 940–980 nm. A thermal analysis was performed using the finite element method to predict temperature distribution. The depth of cut was determined where tensile strength decreased sharply, and the predicted surface temperature is presented in the analysis results. The experiments were performed with conventional machining and laser-assisted machining. Surface roughness, tool wear, and cutting force were evaluated. In contrast to the results of conventional end milling, laser-assisted end milling improved surface roughness. Moreover, laser-assisted end milling proved more effective than conventional end milling in terms of cutting tool damage. Our results proved that heat assistance significantly influenced the magnitude of the cutting forces—while the actual reduction in forces varied slightly depending on the force component, cutting tool, and cutting conditions, force components showed a reduction of roughly 13–46%.

TOOL LIFE PERFORMANCE OF COATED CARBIDE TOOL ON TITANIUM ALLOY EXTRA LOW INTERSTITIALS

2015 ◽  
Vol 77 (1) ◽  
Author(s):  
R. Zuraimi ◽  
M. A. Sulaiman ◽  
T. Joseph Sahaya Anand ◽  
E. Mohamad ◽  
C. H. Che Haron
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Chemical Vapor ◽  
Corrosion Property ◽  
Depth Of Cut ◽  
Coated Carbide

The Titanium alloys (Ti-6Al-4V) has been employed in a variety of applications, particularly in the aerospace, automotive, medical and chemical industries, primarily because of its high strength to weight ratio, high resistance to fracture, and exceptional anti-corrosion property. However, Ti-6Al-4V cannot be easily machined even at a high temperature as it has a low thermal conductivity and low elastic modulus, and may react chemically with the coating on the cutting tool. The objective of this study was to investigate the cutting tool life performance in the turning of Ti-6Al-4V Extra Low Interstitials (ELI) using a Chemical Vapor Deposition (CVD) carbide cutting tool in dry conditions. The Factorial method was used as the basis for the experimental design of this study. A factorial design with two levels was chosen for the arrangement of the cutting parameters, which comprised a cutting speed of between 100 to 140 m/min, a feed rate of between 0.15 to 0.20 mm/rev, and a fixed depth of cut of 0.35 mm. A three-axis microscope was used to measure the flank wear for every 20 mm on the workpiece until the ISO criterion was arrived at by the flank wear (Vb). The results indicated that the maximum tool life of 20.68 minutes was achieved at a cutting speed of 100 m/min and a feed rate of 0.15 mm/rev.

Fuzzy Rule Based Modeling for Surface Roughness in Machining of Titanium Alloy Using Nano Coated Carbide Inserts

2015 ◽  
Author(s):  
J. Nithyanandam ◽  
K. Palanikumar ◽  
Sushil Lal Das
Keyword(s):  
Surface Roughness ◽  
Fuzzy Logic ◽  
Titanium Alloy ◽  
Chemical Reactivity ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Depth Of Cut ◽  
Work Piece ◽  
Nose Radius ◽  
Coated Carbide

Titanium and its alloys are used in many industrial and engineering applications because of their good properties, such as high strength to weight ratio, excellent fracture and corrosion resistance. The major application of titanium has been in the aerospace industry. When turning of titanium alloys with conventional tools, the tool wear rate increases, because of high chemical reactivity and strong adhesion between the tool and work piece materials. The nano coated carbide cutting tool is used for the turning experiment. The cutting parameter for the experimental works are cutting speed, feed rate, nose radius, and depth of cut. Fuzzy logic modeling is used for the prediction of surface roughness in machining of titanium alloy. From the results, the Fuzzy logic model is the best suited method for modeling the turning parameters of titanium alloy by using Nanocoated carbide tools.

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