Tool Diffusion Wear Mechanism in High Efficiency Machining Ti6Al4V

2013 ◽  
Vol 579-580 ◽  
pp. 3-7
Author(s):  
Yi Hang Fan ◽  
Zhao Peng Hao ◽  
Min Li Zheng ◽  
Feng Lian Sun ◽  
Suo Liang Niu
Keyword(s):  
High Efficiency ◽  
Diffusion Mechanism ◽  
Cutting Temperature ◽  
Tool Material ◽  
Machining Process ◽  
Rake Face ◽  
Workpiece Material ◽  
Machined Surface ◽  
Diffusion Wear ◽  
Flank Face

Ti6Al4V has great affinity with tool material in machining process, which easily leads to tool diffusion wear. Turning experiments were carried out to study cutting temperature and pressure at tool-chip/workpiece. Based on the analysis, a scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectrometer (EDS) was used to analyze tool wear morphology. The affinity of tool and workpiece material using the Ti-W, Ti-Co diagram was also studied to elaborate the diffusion mechanism in this present study. The results shows that the cutting temperature is very high and the temperature increases with the increase of cutting speeds in machining Ti6Al4V. At the contact area, the highest temperature is located in tool rake face near to tool tip. The resilience of workpiece results in serious attrition between tool flank face and the machined surface. The highest pressure is located in tool flank face near to tool tip and the pressure in tool-workpiece interface is much higher than that in tool-chip interface. Under the high cutting temperature and high pressure at tool-chip/workpiece interface, diffusion occurred both at tool rake an flank face in machining Ti6Al4V. Because of the higher temperature at tool rake face diffusion at tool rake face ia more sever than that at tool flank face.

Simulation of Machining of Incoloy 907 Based on Thermodynamical Constitutive Equation

2013 ◽  
Vol 631-632 ◽  
pp. 681-685
Author(s):  
Fang Shao ◽  
Fa Qing Li ◽  
Hai Ying Zhang ◽  
Xuan Gao
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Tool Material ◽  
High Reactivity ◽  
Good Prediction ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting ◽  
Cutting Tool Materials

Aero-engine alloys (also as known as superalloys)are known as difficult-to-machine materials, especially at higher cutting speeds, due to their several inherent properties such as low thermal conductivity and their high reactivity with cutting tool materials. In this paper a finite element analysis (FEA) of machining for Incoloy907 is presented. In particular, the thermodynamical constitutitve equation(T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and cutting force are predicted. The comparison between the predicted and experimental cutting temperature and cutting force are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and cutting force can be achieved by the method of FEA with thermodynamical constitutitve equation.

Diffusion and Oxidation Wear of PCBN Tool when Cutting Materials Difficult-to-Cut Based on Thermodynamics

2014 ◽  
Vol 538 ◽  
pp. 54-57
Author(s):  
Fang Shao ◽  
Yu Ting Wang ◽  
Li Jing Zou ◽  
Yan Ying Wu ◽  
Dong Sun
Keyword(s):  
High Temperature ◽  
High Speed ◽  
Cutting Temperature ◽  
Tool Material ◽  
Diffusion Reaction ◽  
Depth Of Cut ◽  
Pcbn Tool ◽  
Diffusion Wear ◽  
Pcbn Tools ◽  
Oxidation Wear

Cutting temperature always highly reaches over to 1000°C when high speed machining with PCBN tools. Diffusion of tool material element may have important influence on tool wear at such high temperature, the diffusion wear and oxidation wear have become the major wear mechanism. In this paper, the rules of diffusion wear and oxidation wear for PCBN cutting tools are proposed and analyzed based on thermodynamics theory. Dissolution concentrations in typical normal workpice materials of PCBN tool material at different temperature are then calculated. Diffusion reaction rules in high temperature are developed and analyzed using Gibbs free energy criterion. The machining tests were conducted using the PCBN tools at different cutting speeds of 50, 95,100 and 180 m/min, feed of 0.1, 0.2 and depth of cut of 0.1, 0.8, 1, and 1.5 mm respectively on PUMA300LM numerically-controlled lathe. It was found that the theoretical results were uniform with the experimental data; the results will provide useful references for tool material design and selection.

Theoretical Analysis and Experimental Verification of Validity Finished by Abrasive Jet with Grinding Wheel as Restraint

2008 ◽  
Vol 53-54 ◽  
pp. 39-44
Author(s):  
Chang He Li ◽  
Shi Chao Xiu ◽  
Yu Cheng Ding ◽  
Guang Qi Cai
Keyword(s):  
Ground Surface ◽  
Hydrodynamic Pressure ◽  
Machining Process ◽  
Grinding Wheel ◽  
Workpiece Material ◽  
Machined Surface ◽  
Mean Values ◽  
Work Surface ◽  
Geometry Parameter ◽  
Parameter Values

The integration manufacturing technology is a kind of compound precision finishing process that combined grinding with abrasive jet finishing, in which inject slurry of abrasive and liquid solvent into grinding zone between grinding wheel and work surface under no radial feed condition when workpiece grinding were accomplished. The abrasive particles are driven and energized by the rotating grinding wheel and liquid hydrodynamic pressure and increased slurry speed between grinding wheel and work surface to achieve micro removal finishing. In the paper, the machining process validity was verified by experimental investigation. Experiments were performed with plane grinder M7120 and workpiece material 40Cr steel which was ground with the surface roughness mean values of Ra=0.6μm. The machined surface morphology was studied using Scanning Electron Microscope (SEM) and metallography microscope and microcosmic geometry parameters were measured with TALYSURF5 instrument respectively. The experimental results show the novelty process method, not only can obviously diminish longitudinal geometry parameter values of ground surface, but also can attain isotropy surface and uniformity veins at parallel and perpendicular machining direction. Furthermore, the finished surface has little comparability compared to grinding machining surface and the process validity was verified.

Research and Application on High Efficiency Reversible Cutting Technique

2004 ◽  
Vol 471-472 ◽  
pp. 825-829
Author(s):  
Wen Ge Wu ◽  
Si Qin Pang ◽  
Qi Xun Yu
Keyword(s):  
High Efficiency ◽  
Cutting Tool ◽  
Handling Time ◽  
Cutting Parameters ◽  
Machining Process ◽  
Processing Route ◽  
Rough Machining ◽  
Machined Surface ◽  
Primary Motion ◽  
The Way

Reversible cutting method is a research thesis proposed to shorten processing route, decrease tool number and handling time, increase machining efficiency. There are three movement ways, i.e. reversible feed motion, reversible primary motion and reversible composite motion. Primary motion is done by workpiece, conventional or reversible feed motion is done by cutting tool in the way of reversible feed motion, e.g. turning. Cutting velocity is passed to cutting tool, clockwise or anti-clockwise cutting movement is done by cutting tool in the way of reversible primary motion, e.g. milling, shaping, drilling (spade drill), reaming. Primary and feed motions are all reversible in composite motion, e.g. turn-milling. Chip deformation and machined surface with reversible finishing is discussed. A mechanical analysis is carried out to the workpiece deformation of slender shaft turning in normal direction and reversible direction. The result has been verified by experiments. Experimental data for the range of cutting parameters tested showed that the reversible fine machining produce the compressive residual stresses at the surface, which are critical in the performance of the machined components. Experimental research indicted that the results of micro-hardness of reversible fine machining technique are smaller than that of general fine machining show that decreased plastic deformation of the surface layer and work-hardening. It can be adopted such planning which rough machining during advance stroke and fine machining during return stroke in machining process.

Prediction on Cutting Heat of the Simulation in NC Lathe

2012 ◽  
Vol 217-219 ◽  
pp. 1978-1982
Author(s):  
Jing Li ◽  
Yang Jiao ◽  
Zhan Li Wang ◽  
Fu Zhi Huang
Keyword(s):  
Cutting Temperature ◽  
Machining Process ◽  
Deformation Analysis ◽  
Operating Life ◽  
Machined Surface ◽  
Finite Element Software ◽  
Cutting Heat ◽  
Changing Trend ◽  
Variable Condition ◽  
Physical Phenomena

Cutting heat and cutting temperature are the most important physical phenomena in cutting machining process. Cutting temperature and its distribution affect the abrasion of cutting tool and the operating life directly. Meanwhile they can affect the machining precision and the machined surface quality. In this paper the ABAQUS finite element software is used to predict the thermal distribution and variable condition, moreover it is tested through the experiment. As is shown from the result, the changing trend of cutting temperature by the simulation is consistent with the real measured result, which has better precision and reliability and supplies the theoretical basis for the deformation analysis caused by cutting heat in the cutting machining process.

Control of Machining Process for Titanium Alloy Based on Green Cooling and Lubricating Technology

2012 ◽  
Vol 580 ◽  
pp. 7-11
Author(s):  
Yue Zhang ◽  
Li Han ◽  
You Jun Zhang ◽  
Xi Chuan Zhang
Keyword(s):  
Titanium Alloy ◽  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Small Diameter ◽  
Machining Process ◽  
Machined Surface ◽  
Cutting Zone ◽  
Cutting Experiments ◽  
Special Control

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. The cutting experiments are carried out based on green cooling and lubricating technology. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface. And it can help to chip forming and breaking. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy.

Simulation of Machining of Incoloy 907 with Thermodynamical Constitutive Equation

2013 ◽  
Vol 634-638 ◽  
pp. 1790-1793
Author(s):  
Fang Shao ◽  
Hai Ying Zhang ◽  
Zhi Jun Fan
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Tool Material ◽  
High Reactivity ◽  
Good Prediction ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting ◽  
Cutting Tool Materials

Aero-engine alloys (also as known as superalloys)are known as difficult-to-machine materials, especially at higher cutting speeds, due to their several inherent properties such as low thermal conductivity and their high reactivity with cutting tool materials. In this paper a finite element analysis (FEA) of machining for Incoloy907 is presented. In particular, the thermodynamical constitutitve equation(T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and cutting force are predicted. The comparison between the predicted and experimental cutting temperature and cutting force are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and cutting force can be achieved by the method of FEA with thermodynamical constitutitve equation.

Study on Parameters Optimization of Ceramic Machining Process

2011 ◽  
Vol 418-420 ◽  
pp. 1338-1341
Author(s):  
Qiang Wang ◽  
Ying Ying Zeng ◽  
Xu Guang Min
Keyword(s):  
High Efficiency ◽  
Low Cost ◽  
Cutting Speed ◽  
Tool Material ◽  
Parameters Optimization ◽  
Machining Process ◽  
Impact Factors ◽  
Surface Model ◽  
Optimal Parameters ◽  
Ceramic Machining

The response surface model is established through application of surface response method, then the main impact factors of ceramic machining are determined, and the process parameters are optimized. The mechanical machining technology of ceramic materials is analyzed, and the corresponding optimal parameters are proposed by cutting tool material, rake angle, clearance angle and edge angle, and three cutting elements as cutting speed, cutting depth and feed. Accord to the optimal parameters, high efficiency, good quality and low cost results can be achieved to machine ceramic parts.

Diffusion and Oxidation Wear of Superhard Cutting Tool Based on Thermodynamics Solubility

2014 ◽  
Vol 536-537 ◽  
pp. 1417-1420
Author(s):  
Fang Shao ◽  
Yu Ting Wang ◽  
Li Jing Zou ◽  
Yan Ying Wu ◽  
Chuan He
Keyword(s):  
High Temperature ◽  
High Speed ◽  
Cutting Temperature ◽  
Tool Material ◽  
Material Design ◽  
Diffusion Reaction ◽  
Depth Of Cut ◽  
Diffusion Wear ◽  
Pcbn Tools ◽  
Oxidation Wear

Cutting temperature always highly reaches over to 1000°C? when high speed machining with PCBN tools. Diffusion of tool material element may have important influence on tool wear at such high temperature, the diffusion wear and oxidation wear have become the major wear mechanism. In this paper, the rules of diffusion wear and oxidation wear for PCBN cutting tools are proposed and analyzed based on thermodynamics theory. Dissolution concentrations in typical normal workpiece materials of PCBN tool material at different temperature are then calculated. Diffusion reaction rules in high temperature are developed and analyzed using Gibbs free energy criterion. The machining tests were conducted using the PCBN tools at different cutting speeds of 50, 95,100 and 180 m/min, feed of 0.1, 0.2 and depth of cut of 0.1, 0.8, 1, and 1.5 mm respectively on PUMA300LM numerically-controlled lathe. It was found that the theoretical results were uniform with the experimental data; the results will provide useful references for tool material design and selection.

scholarly journals Deformation Structures and Tool Wear during High-Speed Machining

2013 ◽  
Vol 10 (1) ◽  
pp. 12-17
Author(s):  
Karol Vasilko
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Tool Material ◽  
Machining Process ◽  
Surface Dynamics ◽  
Machined Surface ◽  
Deformation Structures ◽  
Cutting Speeds ◽  
Tool Durability

Abstract Tendencies towards increasing cutting speeds during machining can be observed recently. The first wave of increasing cutting speeds occured in the 60s of the previous century. However, suitable tool material was not available at that time. Increasing cutting speed is possible only following the development of cutting material, resistant against high temperatures, abrasive, adhesive and diffusive wear. It is obvious that the process of chip creation, quality of machined surface, dynamics of machining process and temperature of cutting change considerably with cutting speed. To be able to apply higher cutting speeds in production machining, it is necessary to know the dependence of those characteristics on cutting speed. Some of those phenomena, which are linked with cutting speed, will be explained in the paper. Key words: machining, cutting speed, tool durability, surface quality

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