Multi-Objective Optimization on Drilling of Titanium Alloy (Ti6Al4V)

2013 ◽  
Vol 763 ◽  
pp. 29-49 ◽  
Author(s):  
A. Prabukarthi ◽  
V. Krishnaraj ◽  
M. Senthil Kumar
Keyword(s):  
Titanium Alloy ◽  
Thrust Force ◽  
Optimization Technique ◽  
Weight Ratio ◽  
High Strength ◽  
Hole Diameter ◽  
Machining Process ◽  
Multi Objective ◽  
Titanium Alloy Ti6al4v ◽  
Exit Burr

Titanium alloys present superior properties like resistance to corrosion, high strength to weight ratio etc, but possess poor machinability. Titanium alloy Ti-6Al-4V is the most commonly used titanium alloy in aerospace and medical device industries. Titanium and its alloys are notorious for their poor thermal properties and are classified as difficult-to-machine materials. Drilling is an important machining process since it is involved in nearly all titanium applications. It is desirable to develop optimized drilling processes for Ti and improve the hole characteristics such as hole diameter, circularity and exit burr of currently available processes. Due to the low machinability of the alloys under study, selecting the machining conditions and parameters is crucial. The range of spindle speed and feed rate, which provide a satisfactory tool life, is very limited. The hole quality (hole diameter and circularity), thrust force, torque and exit burr were evaluated at various spindle speeds, feed rates combinations. The optimized parameter is chosen using the multi-objective weighted sum optimization technique.

Investigation of Thrust Forces, Torque and Chip Microstructure during Drilling of Ti-6Al-4V Titanium Alloy

2015 ◽  
Vol 787 ◽  
pp. 431-436 ◽  
Author(s):  
K. Sushinder ◽  
P.R. Shivaram ◽  
S.B. Nivedh Kannaa ◽  
Nisarg Gupta ◽  
K.S. Vijay Sekar
Keyword(s):  
Titanium Alloy ◽  
Thrust Force ◽  
Cutting Tools ◽  
Weight Ratio ◽  
Chip Morphology ◽  
High Strength ◽  
High Reactivity ◽  
Machining Process ◽  
Engine Components ◽  
Thrust Forces

Titanium Alloys are unique due to their high strength-weight ratio,good fracture and corrosion resistance characteristics.They form a significant metal portion of the aircraft structural and engine components. However, their low thermal conductivity and high reactivity with cutting tools during machining, makes them difficult-to-machine materials. In this work, an investigationof the thrust force, torque and chip morphology in drilling of Ti6Al4V, titanium alloy using tungsten carbide tipped drill has been carried out at varying cutting speeds of 19.4, 27.14, 43.41 and 67.82m/min at a constant feed rate of 0.15mm/rev.The machinability, work hardening and thermal softening effects of titanium alloy, during drilling, has been analysed through the effects of the machining process on the thrust force, torque and chip microstructure.

Optimization of Machining Process Parameters in Drilling of CFRP Using Multi-Objective Taguchi Technique, TOPSIS and RSA Techniques

2017 ◽  
Vol 25 (3) ◽  
pp. 185-192 ◽  
Author(s):  
K. Shunmugesh ◽  
K. Panneerselvam
Keyword(s):  
Mathematical Model ◽  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Weight Ratio ◽  
High Strength ◽  
Performance Characteristics ◽  
Machining Process ◽  
Taguchi Technique ◽  
Multi Objective

Carbon Fiber Reinforced Polymer (CFRP) are widely used in many engineering applications as replacement for various other elements to make use of the advantage of its high strength-weight ratio, durability and high corrosion resistance. The paper herein is an attempt to evaluate the drilling characteristics of CFRP by means of three different drill bit types (HSS, TiAlN and TiN) using Taguchi L27 (313) orthogonal array under dry condition. Firstly, the machining process parameters (cutting speed and feed rate) are optimized with multiple performance characteristics using Multi-objective Taguchi technique and TOPSIS. Secondly, mathematical model is developed to correlate the machining process parameters and the performance characteristics (surface roughness, circularity and cylindricity) using response surface analysis. ANOVA is used to validate the developed mathematical model of the responses. The investigation reveals that the results of TOPSIS technique are in good agreement with the multi-objective Taguchi technique and also feed rate is the most predominant factor which affects the responses.

scholarly journals Revealing the WEDM Process Parameters for the Machining of Pure and Heat-Treated Titanium (Ti-6Al-4V) Alloy

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2292
Author(s):  
Nitin Kumar Gupta ◽  
Nalin Somani ◽  
Chander Prakash ◽  
Ranjit Singh ◽  
Arminder Singh Walia ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Electrical Discharge Machining ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Weight Ratio ◽  
High Strength ◽  
Machining Parameters ◽  
Beta Titanium Alloy ◽  
Wide Range ◽  
Wedm Process

Ti-6Al-4V is an alloy that has a high strength-to-weight ratio. It is known as an alpha-beta titanium alloy with excellent corrosion resistance. This alloy has a wide range of applications, e.g., in the aerospace and biomedical industries. Examples of alpha stabilizers are aluminum, oxygen, nitrogen, and carbon, which are added to titanium. Examples of beta stabilizers are titanium–iron, titanium–chromium, and titanium–manganese. Despite the exceptional properties, the processing of this titanium alloy is challenging when using conventional methods as it is quite a hard and tough material. Nonconventional methods are required to create intricate and complex geometries, which are difficult with the traditional methods. The present study focused on machining Ti-6Al-4V using wire electrical discharge machining (WEDM) and conducting numerous experiments to establish the machining parameters. The optimal setting of the machining parameters was predicted using a multiresponse optimization technique. Experiments were planned using the response surface methodology (RSM) technique and analysis of variance (ANOVA) was used to determine the significance and contribution of the input parameters to changes in the output characteristics (cutting speed and surface roughness). The cutting speed obtained during the processing of the annealed titanium alloy using WEDM was quite large as compared to the cutting speed obtained in the case of processing the pure, quenched, and hardened titanium alloys using WEDM. The maximum cutting speed obtained while processing the annealed titanium alloy was 1.75 mm/min.

Experiments of Drilling Titanium Alloy with Varying Operation Parameters

2017 ◽  
Vol 748 ◽  
pp. 254-258
Author(s):  
Chang Yi Liu ◽  
Bai Shou Zhang ◽  
Suman Shrestha
Keyword(s):  
Titanium Alloy ◽  
Feed Rate ◽  
Thrust Force ◽  
Maximum Amount ◽  
Spindle Speed ◽  
Drilling Process ◽  
Process Variables ◽  
Experimental Cutting ◽  
Operation Parameters ◽  
Titanium Alloy Ti6al4v

Drilling experiments of titanium alloy Ti6Al4V were conducted. Taking the speed and feed as the process variables, a set of experimental cutting forces are obtained and compared. From the experimental results it is concluded that within the experimental extent the thrust force and torque of drilling process rises with the feed rate. The lower spindle speed resulted in the greater amount of thrust. Feed rates have greater influence on the thrust force than the spindle speed. The combination of greater feed rate and lower spindle speed results in the maximum amount of thrust. However, combination of greater feed rate and spindle speed resulted in maximum amount of torque.

Effect of Coolant Pressure on Machinability of Titanium Alloy Ti6Al4V

2016 ◽  
Vol 826 ◽  
pp. 82-87 ◽  
Author(s):  
Sandip Patil ◽  
Swapnil Kekade ◽  
Pravin Pawar ◽  
Swapnil Pawar ◽  
Rajkumar Singh
Keyword(s):  
Titanium Alloy ◽  
Chemical Reactivity ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Machining Process ◽  
Mechanism Analysis ◽  
Band Formation ◽  
Titanium Alloy Ti6al4v ◽  
High Pressure Coolant ◽  
Coolant System

Titanium alloy Ti6Al4V comes with several desirable and undesirable properties. Its low thermal conductivity and high chemical reactivity makes it difficult for machining producing high cutting temperature and adhesion tendency. Cutting fluids are used to remove the heat generated at the chip tool interface during the machining process. The coolant with low pressure and improper delivery is not able to break the vapor barrier created by high cutting temperature. The current research investigates the effect of using high pressure coolant system (60 Bar) on the machinability of Ti6Al4V. The machinability was measured in terms of chip breaking, chip thickness, surface finish, tool wear, etc. A detailed statistical and chip mechanism analysis was performed emphasizing the phenomenon of shear band formation, crack formation, chip thickness, chip serration frequency, etc.

High Fugacity Hydrogen Effects in Beta-21S Titanium Alloy

2007 ◽  
Vol 546-549 ◽  
pp. 1355-1360
Author(s):  
Dan Eliezer ◽  
E. Tal-Gutelmacher ◽  
Lothar Wagner
Keyword(s):  
Titanium Alloy ◽  
Weight Ratio ◽  
Thermal Desorption Spectroscopy ◽  
High Strength ◽  
Advanced Materials ◽  
X Ray Diffraction ◽  
Hydrogen Induced Cracking ◽  
Second Phases ◽  
Rolled Condition ◽  
Hot Rolled

Beta-21S titanium alloy is ranked among the most important advanced materials for a variety of technological applications, due to its combination of a high strength/weight ratio, good corrosion behavior and oxidation resistance. However, in many of these technological applications, this alloy is exposed to environments which can act as sources of hydrogen, and consequently, severe problems may arise. The objective of this paper is to investigate the influence of high fugacity hydrogen on Beta-21S alloy in as-received (mill-annealed and hot-rolled) condition. Hydrogen effects on the microstructure are studied using X-ray diffraction and electron microscopy, while the absorption and desorption characteristics are determined respectively by means of a hydrogen determinator and thermal desorption spectroscopy. Preliminary results at room temperature revealed hydrogen-induced straining and expansion of the lattice parameters. However, neither second phases formation (hydrides), nor hydrogen-induced cracking, were observed after hydrogenation. The main characteristics of hydrogen absorption/desorption behavior, as well as hydrogen-induced microstructural changes in both microstructures are discussed in detail.

Effect of Cryogenic Conditions on the Drilling Performance of Carbon-Carbon (C-C) Composites

2017 ◽  
Author(s):  
Y.-Q. Wang ◽  
L.-S. Han ◽  
H.-B. Liu ◽  
K. Li ◽  
Y. Ma
Keyword(s):  
Thrust Force ◽  
High Hardness ◽  
High Strength ◽  
Spray Cooling ◽  
Machining Process ◽  
Drilling Performance ◽  
Drilling Quality ◽  
Composite Drilling ◽  
Positive Effect ◽  
Cryogenic Conditions

C-C composite is a kind of typical difficult-to-machine materials due to its high hardness, high strength, and obvious anisotropy features. But, water-based or oil-based coolant cannot be used during its machining process. As a result, the machining defects, including burrs, orifice ripping, and interlayer delamination, are always unavoidable. In this article, taking the liquid nitrogen as coolant, C-C composite cryogenic drilling is researched experimentally. Taking the way of LN2 external spray cooling, a series of cryogenic drilling experiments were designed. Comparing with dry drilling, the thrust force was reduced, the machining defects were significantly inhibited, and a better roundness of holes was achieved in cryogenic drilling. It indicates that cryogenic condition has a positive effect on improving the C-C composite drilling quality.

scholarly journals Towards Analysis and Optimization during Machining Hardened Steel AISI 4140 with Self-Propelled Rotary Tools

2021 ◽  
Author(s):  
Waleed Ahmed ◽  
Hussien Hegab ◽  
Atef Mohany ◽  
Hossam Kishawy
Keyword(s):  
Tool Wear ◽  
Inclination Angle ◽  
Removal Rate ◽  
Weight Ratio ◽  
High Strength ◽  
Hardened Steel ◽  
Machining Process ◽  
Nsga Ii ◽  
Aisi 4140 ◽  
Steel Aisi

Abstract It is necessary to improve the machinability of difficult-to-cut materials such as hardened steel, nickel-based alloys, and titanium alloys as these materials offer superior properties such as chemical stability, corrosion resistance, and high strength to weight ratio, making them indispensable for many applications. Machining with self-propelled rotary tools (SPRT) is considered as one of the promising techniques used to provide proper tool life even under dry conditions. In this work, an attempt has been performed to analyze, model, and optimize the machining process of AISI 4140 hardened steel using self-propelled rotary tools. Experimental analysis has been offered to (a) compare the fixed and rotary tools performance, and (b) study the effect of the inclination angle on the surface quality and tool wear. Moreover, the current study implemented some artificial intelligence-based approaches (i.e., genetic programming and NSGA-II) to model and optimize the machining process of AISI 4140 hardened steel with self-propelled rotary tools. The feed rate, cutting velocity, and inclination angle are selected to be the design variables, while the tool wear, surface roughness, and material removal rate (MRR) are the studied outputs. Moreover, different weights have been assigned for the three studied outputs to offer different optimized solutions based on the designer interest (equal-weighted, finishing, and productivity scenarios). It should be stated that the findings of the current work offer valuable recommendations to select the optimized cutting conditions when machining hardened steel AISI 4140.

scholarly journals FAST-forge of novel Ti-6Al-4V/Ti-6Al-2Sn-4Zr-2Mo bonded, near net shape forgings from surplus AM powder

2020 ◽  
Vol 321 ◽  
pp. 03010
Author(s):  
Oliver Levano ◽  
Nicholas Weston ◽  
Jacob Pope ◽  
Adam Tudball ◽  
David Lunn ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Hot Forging ◽  
Weight Ratio ◽  
High Strength ◽  
Aerospace Sector ◽  
Near Net Shape ◽  
Stress States ◽  
Field Assisted Sintering ◽  
Corrosive Resistance

Titanium alloys are used extensively in the aerospace sector due to the good combination of high strength-to-weight ratio and corrosive resistance. Many aerospace components are exposed to extreme service stress states and temperatures, which in some applications could compromise the component’s performance if a single titanium alloy is used. A potential solution to this issue could be the combination of dissimilar titanium alloys in subcomponent regions, achieved through consolidating powders via field assisted sintering technology (FAST-DB) and subsequent hot forging (FAST-forge). In this paper, near net shape titanium-titanium alloy demonstrator components are produced from oversized AM powders in just two hybrid solid-state steps; FAST-DB and hot forging.

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