Investigation of Machinability in Milling of Difficult-to-Cut Materials Using Water Soluble and Water Insoluble Cutting Oil

2015 ◽  
Vol 656-657 ◽  
pp. 308-313
Author(s):  
Makoto Nikawa ◽  
Masato Okada
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Hard Metal ◽  
Milling Process ◽  
Water Soluble ◽  
Dry Cutting ◽  
Abrasion Test ◽  
The Face ◽  
Pin On Disk ◽  
Cutting Point

The machinability of difficult-to-cut materials was evaluated during the milling process using water soluble and water insoluble cutting oils. The fundamental characteristics of the cutting oils were investigated by the pin-on-disk abrasion test. The machinability was evaluated by the tool flank wear, chip geometry, cutting force, and tool-flank temperature during milling. The tool-flank temperature was measured using a two-color pyrometer with an optical fiber. Workpiece materials consisting of stainless steel and a titanium alloy were used along with commercial cutting oils. From the results of the pin-on-disk abrasion test, the friction coefficients resulting from the application of various cutting oils to the face of the titanium alloy and WC-based hard metal were approximately the same value. The water soluble cutting oil had a higher coolability than the water insoluble cutting oil. From the results of the milling test, the water insoluble oil had a higher machinability of the difficult-to-cut materials than the water soluble cutting oil. The tool-flank temperature during wet cutting of the difficult-to-cut materials decreased by approximately 50–80 °C compared to dry cutting. However, no differences in the tool-flank temperature were observed between the water soluble and water insoluble cutting oils. The cutting force during wet cutting increased compared to dry cutting, most likely because the heating during cutting was reduced by supplying the cutting oil, and the material at the cutting point did not cause heat softening.

Cutting Characteristics of Binderless Diamond Tools in High-Speed Turning of Ti-6Al-4V – Availability of Single-Crystal and Nano-Polycrystalline Diamond –

2016 ◽  
Vol 10 (3) ◽  
pp. 411-419
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
◽  
Akira Hosokawa ◽  
Takashi Ueda ◽  
Tatsuaki Furumoto ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Single Crystal ◽  
Cutting Force ◽  
High Speed ◽  
Diamond Tool ◽  
Cutting Temperature ◽  
Polycrystalline Diamond ◽  
Water Soluble ◽  
Diamond Tools ◽  
Single Crystal Diamond

In this study, the tool performance of two types of binderless diamond tools – single-crystal diamond (SCD) and nano-polycrystalline diamond (NPD) – is investigated in the high-speed cutting of titanium alloy (Ti-6Al-4V) with a water-soluble coolant. The NPD tool allows for a larger cutting force than the SCD tool by dulling of the cutting edge, despite NPD being harder than SCD. This large cutting force and the very low thermal conductivity of NPD yield a high cutting temperature above 500°C, which promotes the adhesion of the workpiece to the tool face, thereby increasing tool wear. Based on the morphology of the tool edge without scratch marks and the elemental analysis by energy-dispersive X-ray spectroscopy (EDX) of both the flank face and the cutting chips, diffusion-dissolution wear is determined to be the dominant mechanism in the diamond tool. A thin TiC layer seems to be formed in the boundary between the diamond tool and the titanium alloy at high temperatures; this is removed by the cutting chips.

Analysis of Cutting Forces in Helical Milling Process

2011 ◽  
Vol 215 ◽  
pp. 9-13 ◽  
Author(s):  
H.Y. Wang ◽  
Xu Da Qin ◽  
Qi Wang
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Rotational Speed ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Milling Process ◽  
Helical Milling ◽  
Depth Of Cut ◽  
Cutting Experiment ◽  
Tool Cutting

Helical milling is used to generate holes, in which a tool attached to the rotating spindle traverses a helical trajectory, and the diameter of holes will be larger than that of the tool. Based on the principle of helical milling, this paper establishes analytical model of cutting forces. As the cutter travels on the helical path, intersection between the tool and the workpiece changes continuously, in which chip thickness and direction of the cutting forces will vary simultaneously. The cutting forces are not only direct proportional to the axial depth of cut, but also related to the rotational speed and orbital speed of the tool. Cutting experiment is conducted for the titanium alloy. The result shows that the simulated cutting force can be used to predict the change of cutting force under different conditions.

Effect of Milling Parameters and Coolants on Surface Hardness of Tool Steel: SKD 11

2013 ◽  
Vol 650 ◽  
pp. 596-601
Author(s):  
Apichad Inkhamnoi ◽  
Komson Jirapattarasilp
Keyword(s):  
Tool Steel ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Surface Hardness ◽  
Milling Process ◽  
Dry Cutting ◽  
Machined Surface ◽  
Milling Parameters ◽  
The Face

The purpose of this research was to study milling parameters and coolant, which were affecting to surface hardness of tool steel: SKD 11. The experiment was design by conduction of 3 factors and 3 levels. The parameters consisted of three levels of cutting speed and three levels of feed rate. Furthermore, the experiment was done by coolant types. Soluble oil vegetable oil and dry-cutting were used for coolant types in milling. The face milling process was chosen to experiment. Cutting tool was used for this study was inserted carbide with coated polycrystalline vapor deposited (PVD) tools. The finding of main factors and interaction between factors affected to surface hardness was analyzed. Effect of cutting speed and feed rate on surface hardness after milling was discussed. In order to finding suitable of coolant type, effect of coolants on hardness of machined surface was analyzed and compared.

Study on Cutting Forces and Surface Finish During End Milling of Titanium Alloy

2014 ◽  
Author(s):  
Krishnaraj Vijayan ◽  
Samsudeen Sadham ◽  
Saikumar Sangeetha ◽  
Kuppan Palaniyandi ◽  
Redouane Zitoune
Keyword(s):  
Experimental Study ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Cutting Speeds

This paper investigates numerical and experimental study of end milling of titanium alloy Ti–6% Al–4% V using carbide insert based cutting tool. The experiments were carried out under dry cutting conditions. The cutting speeds selected for the experiments are 20,30,40,50 mmin–1. The feed rates used in the experiment were 0.02, 0.04, 0.06 and 0.08 mmrev–1, while depth of cut is kept constant at 1.0 mm. For conducting the experiments single insert based cutting tool is based. For a range of cutting speeds and feeds measurements of cutting force, surface roughness and cutting temperature have been recorded. From the experimental study it can be seen that cutting speed has the significant effect on temperature when compared to feed/tooth. Further it is also found that cutting speed of 30 m min−1 and feed rate of 0.02 mm rev−1 could be used for machining Ti alloy. Moreover the experimental and numerical cutting force values are compared.

Experimental Research of Milling Force and Cutting Temperature of TB2 Titanium Alloy in Liquid Nitrogen Cooling

2016 ◽  
Vol 836-837 ◽  
pp. 36-42 ◽  
Author(s):  
Jing Jing Liu ◽  
Chong Chen ◽  
Yin Fei Yang ◽  
Liang Li ◽  
Wei Zhao
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Liquid Nitrogen ◽  
Cutting Temperature ◽  
Chemical Properties ◽  
Machining Process ◽  
Dry Cutting ◽  
Machine Material ◽  
High Feed ◽  
Liquid Nitrogen Cooling

Titanium alloy is becoming increasingly employed in the aerospace industries due to its good mechanical and chemical properties. As a typical difficult-to-machine material, there are problems of fast tool wear and poor stability of the processing quality in the machining process. Therefore, experiments of high feed milling of TB2 titanium alloy in liquid nitrogen cooling were carried out to measure the cutting force and the cutting temperature. The experimental results showed that under some parameters, liquid nitrogen could decrease the cutting force and cutting temperature in comparison with dry cutting. What’s more, the tool life as well as the surface quality was improved.

The Effects of Curvature Radius on Cutting Force and Stability during End Milling

2011 ◽  
Vol 314-316 ◽  
pp. 1721-1726
Author(s):  
Wan Zhu Liu ◽  
Qiang Liu ◽  
Ge Gao ◽  
Xue Yan
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Radius Ratio ◽  
Curvature Radius ◽  
Stable Range ◽  
Large Radius ◽  
Optimal Parameters ◽  
Cutting Point ◽  
End Milling Process

The influence of radius ratio of cutting point and cutter on cutting force and stability during end milling process is presented in this paper. To derive motion equations, a 2 DOF mechanical model of end milling considering both regenerative and self-excited effects was established. Different ratio values during three milling conditions were analyzed. Cutting forces as well as stability under different radius ratios by changing curvature radius and cutter radius were elaborated respectively. The results show that when other parameters are set fixed, cutter with relative large radius has smaller cutting force and larger stable range. Cutters with same radius will overlap on cutting force when radius ratio is large enough even under different milling conditions. The proposed analysis on cutting force and stability can be used to determine the optimal parameters, such as cutter radius and spindle speed etc. to improve the accuracy and productivity.

Process Optimization for Milling Deformation Control of Titanium Alloy Thin-Walled Web

2016 ◽  
Vol 836-837 ◽  
pp. 147-154 ◽  
Author(s):  
Xu Ding ◽  
Ting Ting Chen ◽  
Yin Fei Yang ◽  
Liang Li
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Process Optimization ◽  
Processing System ◽  
Milling Process ◽  
Machining Accuracy ◽  
Load Bearing ◽  
Deformation Control ◽  
Thin Walled ◽  
Titanium Alloy Ti6al4v

The titanium alloy thin-walled structure has been widely used in aircraft construction as one of the main load-bearing components. However, it is difficult to ensure the machining accuracy because of the machining difficulties of materials and structures. This paper takes titanium alloy (Ti6Al4V) thin-walled web as the research object and analyzes the factors of milling deformation. Based on the analysis, the milling process of the titanium alloy thin-walled structure is optimized, including the decrease of cutting force and the increase of processing system rigidity. Furthermore, a reasonable milling scheme is put forward.

On the segmentation-driven vibration in milling titanium alloy

2016 ◽  
Vol 232 (9) ◽  
pp. 1508-1522 ◽  
Author(s):  
Jiahao Shi ◽  
Qinghua Song ◽  
Zhanqiang Liu ◽  
Yi Wan
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Natural Frequency ◽  
End Milling ◽  
Chip Morphology ◽  
Milling Process ◽  
Force Model ◽  
Tool Vibration ◽  
Segmented Chip ◽  
Cutting System

Numerous hard, brittle metals have been shown to form segmented chips during machining operations, which has been shown to be linked to high vibration levels in turning and milling processes. This article concerns quantitative comprehension of segmentation-driven vibration in end-milling process. First, dynamic model of milling process with impact of segmented chip is presented, and a periodic cutting force model related with segmented chip is proposed. Second, for experimental observation, a series of tests are carried out concerning modal test of cutting system; chip morphology, tool vibration during cutting, surface location error, and high-frequency sampling measurements of cutting force signal are realized. The method used for calculating the frequency of segmentation chip by oblique cutting is deduced. It is found that at low feed rate, the periodic cutting force is affected by the natural frequency of cutting system, segmentation chip, and tool vibration. Finally, amplitude–frequency response for quasi-single degree of freedom is employed to elaborate the relationship between segmentation frequency and natural modes of system. The results show that when the ratio (frequency of segmented chip to natural frequency of system) is a noninteger value or above 3, no significant vibrations of cutting system are observed in milling titanium alloy Ti6Al4V.

scholarly journals A development method of cutting force coefficients in face milling process using parallelogram insert

2021 ◽  
pp. 36-52
Author(s):  
Nhu-Tung Nguyen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Theoretical Method ◽  
Milling Process ◽  
Face Milling ◽  
Linear Functions ◽  
Depth Of Cut ◽  
Cutting Force Coefficients ◽  
Force Coefficients ◽  
The Face

This paper presents a modeling method of cutting force and a combination approach of theory and experimental methods in the determination of cutting force coefficients in the face milling process using a parallelogram insert. By the theoretical method, the cutting forces were modeled by a mathematical function of cutting cutter geometry (Cutter diameter, the number of inserts, the insert nose radius, insert cutting edge helix angle, etc.), cutting conditions (depth of cut, feed per flute, spindle speed, etc.), and cutting force coefficients (shear force coefficients, edge force coefficients). By the theoretical method, the average cutting forces in three directions (feed – x, normal – y, and axial – z) were modeled as the linear functions of feed per flute. By the experimental method, the average cutting forces in these three directions were also regressed as the linear functions of feed per flute with quite large determination coefficients (R2 were larger than 92 %). Then, the relationship of average cutting forces and feed per flute was used to determine all six cutting force coefficient components. The validation experiments were performed to verify the linear function of average cutting forces, to determine the cutting force coefficients, and to verify the cutting force models in the face milling process using a cutter with one parallelogram insert. The cutting force models were successfully verified by comparison of the shape and the values of predicted cutting forces and measured cutting forces. These proposed methods and models can be applied to determine the cutting force coefficients and predict the cutting force in the face milling process using a parallelogram insert and can be extended with other cutting types or other insert types

scholarly journals Cutting mechanism of straight-tooth milling process of titanium alloy TC21 based on simulation and experiment

PLoS ONE ◽  
2021 ◽  
Vol 16 (10) ◽  
pp. e0258403
Author(s):  
Zhang Lei ◽  
Lei Pei
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Chip Morphology ◽  
Side Surface ◽  
Milling Process ◽  
Friction Model ◽  
Cutting Process ◽  
Transfer Model ◽  
Cutting Mechanism ◽  
Constitutive Material Model

Due to the characteristics of high strength, high chemical activity and low heat conduction, titanium alloy materials are generally difficult to machine. As a typical titanium alloy with higher strength and lower heat conductivity, the machinability of titanium alloy TC21 is very poor and its cutting process is companied with larger cutting force and rapid tool wear. Straight-tooth milling tool is often used to cut the groove and side surface in the titanium alloy parts. And the milling method can be used to investigate the cutting mechanism because the cutting force has only two components and the better chip morphology is obtained. To investigate the straight-tooth milling process of TC21 alloy, a series of milling force experiments have been done. In addition, a 3D finite element model (FEM) for the straight-tooth milling process of TC21 alloy is presented to simulate the milling process. In the model, the constitutive material model, the failure model, the friction model and the heat transfer model were adopted. Through the simulation, chip formation, stress distribution, cutting force and milling temperature were obtained. The cutting force reaches its maximum when the spindle speed reaches about 13000 rpm, and then decreases as the speed continues to increase. The results confirmed that the similar “Salomon” phenomenon existed in the cutting process of TC21 alloy.

Sign in / Sign up

Export Citation Format

Share Document