High-Speed Turning of Titanium Matrix Composites with PCD and Carbide Tools

2013 ◽  
Vol 770 ◽  
pp. 39-44 ◽  
Author(s):  
Ying Fei Ge ◽  
Jiu Hua Xu ◽  
Yu Can Fu
Keyword(s):  
Tool Life ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Matrix Composites ◽  
Carbide Tool ◽  
High Speed Turning ◽  
Speed Range

High-speed turning tests were performed on vol.10%(TiCp+TiBw)/TC4 composite (TMC) in the speed range of 60-120m/min using PCD and carbide tools to investigate the tool life, tool wear, cutting temperatures and cutting forces. The results showed that the carbide tool was not suit for the machining of TMC. Tool life of PCD was confined to 12 min for all the cutting conditions. Flank wear increased obviously with the increasing cutting speed especially when the cutting speed surpassed 80m/min. PCD tool mainly took place chipping, peeling, abrasive wear and adhesive wear at the rake face and flank. The cutting temperatures of carbide were about 1.5-2.0 times higher than that of the PCD. Under the same cutting condition, cutting temperature of TMC was nearly 100°C higher than that of the TC4 matrix. The cutting forces were confined to 130N and 150N for the PCD and carbide tool respectively. For the carbide the cutting forces slightly decreased when the cutting speed increased from 60m/min to 120m/min. When using the worn tool, the cutting forces significantly decreased with the increasing cutting speed especially for the peripheral force component.

Experimental Investigation on Cutting Forces and Temperature in High Speed Turning of Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17) Alloys

2012 ◽  
Vol 472-475 ◽  
pp. 1054-1058
Author(s):  
Bao Lin Wang ◽  
Xing Ai ◽  
Zhan Qiang Liu ◽  
Ji Gang Liu
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Type Alloy ◽  
High Speed Turning ◽  
Orthogonal Turning ◽  
Coated Carbide ◽  
Cutting Speeds

In this study, orthogonal turning experiments are performed to analyze the machinability of Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), a β-rich, α+β type alloy. PVD TiAlN coated carbide tool inserts are applied, because they are used widely for machining this material. The cutting forces and cutting temperatures are examined under different cutting conditions, which the cutting speeds are varied from 44m/min to 123m/min, the feed rates are 0.06mm/r, 0.08mm/r, 0.10mm/r and 0.12mm/r,respectively.There are some different varying trends of both the cutting force and the thrust force with the change of cutting speed. The cutting temperatures are found to increase with cutting speeds as well as feed rates.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Development of Cutting Tools With Micro-Textured Surface for High Speed Machining of Ti-6Al-4V

2021 ◽  
Author(s):  
Mitsuru Hasegawa ◽  
Tatsuya Sugihara
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Metal Cutting ◽  
Failure Process ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Textured Surface ◽  
Textured Surfaces

Abstract In cutting of Ti-6Al-4V alloy, the cutting speed is limited since a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. On the other hand, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face successfully decreases the cutting temperature, resulting in a significant suppression of both crater wear and flank wear. In addition, the temperature zone where the texture tool is effective in terms of the tool life in the Ti-6Al-4V cutting was discussed.

Studies on Cutting Forces of High Volume Fraction SiCp/Al Composites with Ultrasonic Vibration High Speed Milling

2011 ◽  
Vol 295-297 ◽  
pp. 785-788 ◽  
Author(s):  
Dao Hui Xiang ◽  
Guang Xi Yue ◽  
Xin Tao Zhi ◽  
Hai Tao Liu ◽  
Bo Zhao
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Speed ◽  
High Volume ◽  
High Volume Fraction ◽  
Matrix Composites ◽  
Machining Performance ◽  
High Speed Milling ◽  
Hard Cutting

The orthogonal method was used for analyzing the machining performance of high volume fraction SiCp/Al metal matrix composites (SiCp/Al MMCs) during high speed milling and ultrasonic high speed milling in this paper. The influence of cutting speed, feed rate and cutting depth on 3-directional forces were investigated. The results show that the cutting forces are decreased due to the cutting mechanism of SiCp/Al MMCs is changed from brittle cutting to ductile cutting during ultrasonic high speed milling. In addition, the chips exist in forms of C-type chips because of increasing rake angles. Ultrasonic high-speed milling is a more highly effective hard cutting way compared with high speed milling.

Ultra High Speed Turning of Inconel 718 with Sialon Ceramic Tools

2010 ◽  
Vol 126-128 ◽  
pp. 653-657 ◽  
Author(s):  
Guang Ming Zheng ◽  
Jun Zhao ◽  
Xin Yu Song ◽  
Cao Qing Yan ◽  
Yue En Li
Keyword(s):  
Wear Mechanisms ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Cutting Condition ◽  
Inconel 718 Alloy ◽  
High Speed Turning ◽  
Sialon Ceramic ◽  
Ultra High Speed

This paper explores the wear mechanisms of a Sialon ceramic tool in ultra high speed turning of Nickel-based alloy Inconel 718. Microstructures of the chips are also investigated. Stereo optical microscope and scanning electron microscope (SEM) are employed to observe worn surfaces of the tool produced by various wear mechanisms and morphological features of chips. In addition, the elemental compositions of wear products are evaluated by energy-dispersive X-ray spectroscopy (EDS). As a result of the study, wear mechanisms identified in the machining tests involve adhesive wear and abrasive wear. At the initial stage of cutting process, crater wear and flank wear are the main wear patterns. At the rapid wear stage, the SEM and EDS results showed that the adhered elements of Inconel 718 alloy on the tool rake face such as Ni, Fe and Cr accelerated the tool wear rate. Meanwhile, it was found that the chip morphology was serrated type under ultra high speed cutting condition, furthermore, the tendency of serration of the chip increased with the increase in cutting speed and feed rate.

Research on Adiabatic Shear during Serrated Chip Formation of High Speed Turning of Hardened Steel

2010 ◽  
Vol 139-141 ◽  
pp. 743-747
Author(s):  
Chun Zheng Duan ◽  
Hai Yang Yu ◽  
Min Jie Wang ◽  
Bing Yan ◽  
Yu Jun Cai
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Rake Angle ◽  
Adiabatic Shear ◽  
Cutting Condition ◽  
Serrated Chip ◽  
Serrated Chip Formation

The development of chip morphology, critical cutting condition of adiabatic shear during serrated chip formation and cutting forces were observed and measured by high speed turning experiment for 30CrNi3MoV hardened steel. Results show that the cutting speed and rake angle are leading factors to influence chip morphology and cutting forces. With the increase of cutting speed, the continuous band chip transforms into serrated chip at a certain critical value. As the rake angle is changed from positive to negative, the critical cutting speed of adiabatic shear significantly decreases, the cutting forces abruptly reduces when the serrated chip forms. The results from predicting critical cutting speed using the critical cutting condition criterion of adiabatic shear in metal cutting process show that the leading reason of serrated chip formation is that the adiabatic shear fracture repeatedly occurs in the primary shear zone.

scholarly journals Modeling Cutting Forces in High-Speed Turning using Artificial Neural Networks

TecnoLógicas ◽  
2021 ◽  
Vol 24 (51) ◽  
pp. e1671
Author(s):  
Luis W. Hernández-González ◽  
Dagnier A. Curra-Sosa ◽  
Roberto Pérez-Rodríguez ◽  
Patricia D.C. Zambrano-Robledo
Keyword(s):  
Neural Networks ◽  
Artificial Neural Networks ◽  
Energy Consumption ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machining Time ◽  
High Speed Turning ◽  
Artificial Neural

Cutting forces are very important variables in machining performance because they affect surface roughness, cutting tool life, and energy consumption. Reducing electrical energy consumption in manufacturing processes not only provides economic benefits to manufacturers but also improves their environmental performance. Many factors, such as cutting tool material, cutting speed, and machining time, have an impact on cutting forces and energy consumption. Recently, many studies have investigated the energy consumption of machine tools; however, only a few have examined high-speed turning of plain carbon steel. This paper seeks to analyze the effects of cutting tool materials and cutting speed on cutting forces and Specific Energy Consumption (SEC) during dry high-speed turning of AISI 1045 steel. For this purpose, cutting forces were experimentally measured and compared with estimates of predictive models developed using polynomial regression and artificial neural networks. The resulting models were evaluated based on two performance metrics: coefficient of determination and root mean square error. According to the results, the polynomial models did not reach 70 % in the representation of the variability of the data. The cutting speed and machining time associated with the highest and lowest SEC of CT5015-P10 and GC4225-P25 inserts were calculated. The lowest SEC values of these cutting tools were obtained at a medium cutting speed. Also, the SEC of the GC4225 insert was found to be higher than that of the CT5015 tool.

Experimental Study on High Speed Machining of a Titanium Alloy

2009 ◽  
Vol 69-70 ◽  
pp. 451-455
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Speed ◽  
Fatigue Property ◽  
High Speed Machining ◽  
Ta15 Titanium Alloy ◽  
Milling Tool ◽  
Speed Range

High Speed Machining (HSM) has been proved to be useful in the machining of many materials. This research is concerned with the performance of HSM in the milling of Ti-6.5Al-2Zr-1Mo-1V (TA15) titanium alloy. The tool life and wear mechanism of the milling tool under different cutting speed were investigated, and the influences of cutting speed on the surface integrity and fatigue property of the machined part were studied. According to the experimental results, acceptable tool life can be obtained in a speed range up to 200m/min. The results also show that increasing cutting speed can help to improve the surface integrity and fatigue property of the machined part.

PERFORMANCE OF A COATED CEMENTED CARBIDE TOOL IN HIGH SPEED MILLING OF TI-6AL-4V ALLOY

2013 ◽  
Vol 12 (02) ◽  
pp. 131-146 ◽  
Author(s):  
GUANGYU TAN ◽  
YUHUA ZHANG ◽  
GUANGHUI LI ◽  
GUANGJUN LIU ◽  
YIMING (KEVIN) RONG
Keyword(s):  
Wear Mechanism ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Cemented Carbide ◽  
Thermal Imager ◽  
Carbide Tool ◽  
High Speed Milling ◽  
Cemented Carbide Tool ◽  
Coated Cemented Carbide

A series of experiments were conducted to study the performance of a coated cemented carbide tool in high speed milling of Ti -6 Al -4 V alloy. Experimental measurements of three components of the cutting forces were performed by using a three-component dynamometer. The cutting temperature was measured by using an infrared thermal imager. The variation of cutting forces and cutting temperature with the cutting parameters are investigated. The influence of cutting speed, axial depth of cut, and feed rate on the cutting forces and cutting temperature are analyzed and discussed. The wear patterns of the tool were investigated using scanning electron microscope (SEM) and analysis of energy spectrum, and the wear mechanism is discussed. It is found that abrasive wear and adhesive wear are the dominant wear mechanism of the tool.

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