Investigation of Tool-Wear and Surface Roughness in Turning Ti6Al4V under Different Cooling Lubrication Conditions

2014 ◽  
Vol 800-801 ◽  
pp. 180-185 ◽  
Author(s):  
Teng Da Wang ◽  
Er Liang Liu ◽  
Zhen Li ◽  
Hong Yan Ju ◽  
Yong Chun Zheng
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Chip Morphology ◽  
Protective Role ◽  
Rake Face ◽  
Flank Face ◽  
Lubrication Conditions ◽  
Morphology Influence ◽  
Interaction Relationship

In titanium alloy machining, under different cooling lubrication conditions, the variation of tool wear and chip morphology have a certain effect on the surface roughness. Under different cooling lubrication conditions, in order to analyze the variation of tool wear, chip morphology and surface roughness, the surface roughness values are measured ​​and the variation in tool wear and chip morphology are observed, and then the interaction relationship between the tool wear and the chip morphology is analyzed. The results show that the tool wear and chip morphology influence on the surface roughness. Under different cooling lubrication, the rake face wear do not change significantly, but wet cooling and MQL play a protective role for the flank face wear.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

Effect of Tool Wear on Surface Qualities in Milling of TC4

2016 ◽  
Vol 836-837 ◽  
pp. 132-138 ◽  
Author(s):  
Shu Cai Yang ◽  
Xiao Yang Cui ◽  
Yu Hua Zhang ◽  
Zhi Wei Wang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Quality ◽  
End Milling ◽  
Great Influence ◽  
Chip Morphology ◽  
Milling Process ◽  
Serrated Chip ◽  
Quality Surface

Tool wear is easy occurred in titanium alloy milling process which will affect the surface quality. Surface roughness and surface morphology as an important index to describe and evaluate the surface quality has a great influence on service performance. Therefore, the study on the effect of tool wear on surface qualities is important to improve the surface integrity of titanium alloy parts. Cutting radius of ball-end milling cutter is solved to analyze the effect of tool wear on the cutting radius. The tool wear and the surface qualities of TC4 are achieved through wear experiment. And then the influence law of tool wear on surface qualities and chip morphology are analyzed. The results show that surface roughness value decrease firstly and then increases and that chip morphology with flank wear increase from the unit chip to the serrated chip.

Methodology to Determine Friction in Orthogonal Cutting With Application to Machining Titanium and Nickel Based Alloys

2012 ◽  
Author(s):  
Durul Ulutan ◽  
Tuğrul Özel
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Nickel Alloys ◽  
Orthogonal Cutting ◽  
High Surface ◽  
Lower Surface ◽  
Rake Face ◽  
Surface Residual Stresses ◽  
Flank Face ◽  
Tensile Surface

Friction plays a very important role in machining titanium and nickel alloys. It is the source for the high amount of heat generation, and as a result, the excessive tool wear during machining these materials. The worn tool is known to create lower surface qualities with tensile surface residual stresses and machine-induced hardening at the surface, as well as high surface roughness. It is essential to create a method to determine how and to what extent the friction is built up on the tool. This study facilitates a determination methodology to estimate the friction coefficients between the tool and the chip on the rake face, as well as the tool and the workpiece on the flank face of the tool. The results are validated with experimental results from the titanium alloy Ti-6Al-4V and the nickel alloy IN-100.

Milling Experimental Investigation on Titanium Alloy Ti6Al4V under Different Cooling/Lubrication Conditions

2011 ◽  
Vol 325 ◽  
pp. 406-411 ◽  
Author(s):  
He Yong ◽  
Yu Jing Sun ◽  
Mao Jie Ge ◽  
Jian Feng Li ◽  
Jie Sun
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Chip Morphology ◽  
Nitrogen Adsorption ◽  
Productive Efficiency ◽  
Gas Jet ◽  
Nitrogen Gas ◽  
Chip Surface ◽  
Titanium Alloy Ti6al4v ◽  
Lubrication Conditions

Cooling/lubrication conditions have significant influences on surface integrity, chip morphology, tool life and eventually productive efficiency when machining titanium alloy Ti6Al4V. Milling experiment under different cooling/lubrication conditions, namely dry, wet, MQL and nitrogen gas jet were conducted. Cutting forces, surface roughness and chip morphology are obtained. It is shown that cooling/lubrication conditions influence cutting force greatly while its effect on surface roughness is not obvious. The chip surface contacted with rake face under nitrogen gas is smoother than that under dry, but there exists nitrogen adsorption of the chip at higher speed.

scholarly journals Experimental Investigation on Ultrasonic Atomization Assisted Turning of Titanium Alloy

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 168 ◽  
Author(s):  
Jianbing Meng ◽  
Bingqi Huang ◽  
Xiaojuan Dong ◽  
Yizhong Hu ◽  
Yugang Zhao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Chip Morphology ◽  
Contact Length ◽  
Water Soluble ◽  
Cutting Fluid ◽  
Ultrasonic Atomization ◽  
Cooling And Lubrication

There are high cutting temperatures, large tool wear, and poor tool life in conventional machining, owing to the superior strength and low thermal conductivity of titanium alloy. In this work, ultrasonic atomization assisted turning (UAAT) of Ti6Al4V was performed with a mixed water-soluble oil-based cutting fluid, dispersed into tiny droplets by the high frequency vibration of a piezoelectric crystal. Different cutting speeds and two machining environments, dry and ultrasonic atomization assisted machining, were considered in the investigation of tool life, tool wear morphology, surface roughness, and chip morphology. In comparison with dry machining, UAAT shows lower tool wear and longer tool life due to the advantages of cooling and lubrication. Furthermore, better surface roughness, smoother chip edges, and shorter tool-chip contact length were obtained with UAAT.

scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

scholarly journals Experimental Study of tool Wear Mechanisms in Conventional and High Pressure Coolant Assisted Machining of Titanium Alloy Ti17

2013 ◽  
Vol 554-557 ◽  
pp. 1961-1966 ◽  
Author(s):  
Yessine Ayed ◽  
Guenael Germain ◽  
Amine Ammar ◽  
Benoit Furet
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Rake Face ◽  
High Pressure Coolant

Titanium alloys are known for their excellent mechanical properties, especially at high temperature. But this specificity of titanium alloys can cause high cutting forces as well as a significant release of heat that may entail a rapid wear of the cutting tool. To cope with these problems, research has been taken in several directions. One of these is the development of assistances for machining. In this study, we investigate the high pressure coolant assisted machining of titanium alloy Ti17. High pressure coolant consists of projecting a jet of water between the rake face of the tool and the chip. The efficiency of the process depends on the choice of the operating parameters of machining and the parameters of the water jet such as its pressure and its diameter. The use of this type of assistance improves chip breaking and increases tool life. Indeed, the machining of titanium alloys is generally accompanied by rapid wear of cutting tools, especially in rough machining. The work done focuses on the wear of uncoated tungsten carbide tools during machining of Ti17. Rough and finish machining in conventional and in high pressure coolant assistance conditions were tested. Different techniques were used in order to explain the mechanisms of wear. These tests are accompanied by measurement of cutting forces, surface roughness and tool wear. The Energy-dispersive X-ray spectroscopy (EDS) analysis technique made it possible to draw the distribution maps of alloying elements on the tool rake face. An area of material deposition on the rake face, characterized by a high concentration of titanium, was noticed. The width of this area and the concentration of titanium decreases in proportion with the increasing pressure of the coolant. The study showed that the wear mechanisms with and without high pressure coolant assistance are different. In fact, in the condition of conventional machining, temperature in the cutting zone becomes very high and, with lack of lubrication, the cutting edge deforms plastically and eventually collapses quickly. By contrast, in high pressure coolant assisted machining, this problem disappears and flank wear (VB) is stabilized at high pressure. The sudden rupture of the cutting edge observed under these conditions is due to the propagation of a notch and to the crater wear that appears at high pressure. Moreover, in rough condition, high pressure assistance made it possible to increase tool life by up to 400%.

High Speed Machining of Difficult-to-Machine Materials under Different Lubrication Conditions

2014 ◽  
Vol 625 ◽  
pp. 60-65 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Tatsumi Ohno ◽  
Ryuta Nakatsukasa ◽  
Mamoru Hayashi ◽  
Tomohiko Tabata
Keyword(s):  
Stainless Steel ◽  
Titanium Alloy ◽  
Tool Life ◽  
High Speed ◽  
Life Extension ◽  
Air Jet ◽  
Flank Face ◽  
Air Nozzle ◽  
Carbide Insert ◽  
Lubrication Conditions

This paper describes the applicability of air jet assisted (AJA) machining to stainless steel and titanium alloy at high cutting speeds in terms of tool wear and tool life. A specially designed tool holder with an air nozzle very close to the tool tip was prepared for turning stainless steel. From the experimental results, it was found that the application of flood coolant from the side of the end flank face leads to better result in tool life in AJA machining of stainless steel than that from the side of the side flank face. The assistance of air jet can improve the tool life of the M35 CVD coated insert in machining of the stainless steel by 36 to 100% under the optimal conditions in comparison with wet machining. It was also found that the air jet assistance extended the tool life of the S10 PVD coated insert by 48% in turning titanium alloy. The tool life extension of the coated insert in AJA machining titanium alloy is much longer than that of an uncoated carbide insert.

Experimental Study of Tool Wear during Quasi High Speed Turning Titanium Alloy with Large Cutting Depth

2014 ◽  
Vol 800-801 ◽  
pp. 548-552
Author(s):  
Li Fu Xu ◽  
Wei Liang Dong ◽  
Shu Tao Huang ◽  
Bao Lin Dai
Keyword(s):  
Experimental Data ◽  
Titanium Alloy ◽  
High Speed ◽  
Flank Wear ◽  
Rake Face ◽  
Cutting Depth ◽  
Tool Flank Wear ◽  
High Speed Turning ◽  
Flank Face ◽  
Cutting Speeds

The wear morphology of rake face and flank face of tool is investigated by turning titanium alloy TC4 with CBN solid tool. It has been observed that the main wear form of rake face and flank face of tool is groove wear. The relation between tool flank wear and cutting speeds, feed rate, and cutting depth obtained from experimental data is given.

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