scholarly journals Influence of Wear and Tool Geometry on the Chatter, Cutting Force, and Surface Integrity of TB6 Titanium Alloy with Solid Carbide Cutters of Different Geometry

2020 ◽  
Vol 66 (12) ◽  
pp. 709-723
Author(s):  
Jianyong Liu ◽  
Jianfei Sun ◽  
Uzair Khaleeq uz Zaman ◽  
Wuyi Chen
Keyword(s):  
Residual Stress ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Surface Integrity ◽  
Geometric Structure ◽  
Tool Geometry ◽  
Structure Parameters ◽  
Variable Helix ◽  
Tb6 Titanium Alloy ◽  
End Mills

In this paper, vibration-free milling cutters (variable helix (VH) and variable pitch (VP) end mills) and standard (SD) end mills are used to machine TB6 (Ti-10V-2Fe-3Al) titanium alloy in order to study the influence of wear and geometric structure parameters of milling cutters on chatter, cutting force and surface integrity of machined surfaces. The results of the tests show that the wear of milling cutters has a significant influence on the chatter, cutting force, roughness, residual stress, and microhardness. Geometric structure parameters of milling cutters also have a clear impact on both chatter and cutting force. Also, chatter and cutting force have significant effects on roughness and residual stress, which are in turn affected by tool geometric structure parameters, separately.

scholarly journals Cutting force analysis in machining of titanium alloy with solid carbide cutters of different geometriy

2018 ◽  
Vol 179 ◽  
pp. 02002
Author(s):  
Liu Jianyong ◽  
Qiao Lihong ◽  
Chen Wuyi
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Geometric Structure ◽  
Tangential Force ◽  
Cutting Parameters ◽  
Radial Force ◽  
Structure Parameters ◽  
Milling Cutter ◽  
Solid Carbide ◽  
Tangential Forces

In order to study the cutting force in machining of titanium alloy with solid carbide cutters of different geometriy, variable helix (VH), variable pitch (VP) and standard (SD) milling cutter were used to machine titanium alloy TB6 via dry milling. The influence of cutting parameters and geometric structure parameters of milling cutters on the cutting force was investigated by the analysis of radial and tangential forces in the cutting process with three kinds of milling cutters. The experiment results showed that cutting parameters had the same influence on the radial force and tangential force of the three milling cutters, and the influence of geometric structure parameters on radial force and tangential force was different. Compared with the SD milling cutter, the change of pitch and helix resulted in the increase of radial and tangential forces, the pitch change led to the radial force being larger than the tangential force, and the helix change led to the radial force being smaller than the tangential force.

Experimental Study on Prestressed Cutting of Alloy Ring Parts

2016 ◽  
Vol 836-837 ◽  
pp. 71-76
Author(s):  
Rui Tao Peng ◽  
Yang Ge Li ◽  
Xin Zi Tang ◽  
Zhuan Zhou
Keyword(s):  
Residual Stress ◽  
Titanium Alloy ◽  
Stress Distribution ◽  
Cutting Force ◽  
Surface Integrity ◽  
Compressive Residual Stress ◽  
Machining Process ◽  
Residual Tensile Stress ◽  
Machined Surface ◽  
Cutting Method

In order to solve the poor cutting performance for the titanium alloy and the serious residual tensile stress distribution on the machined surface in cutting titanium alloy, the utilization of prestressed cutting method is proposed to actively control the residual stress distribution status on the machined surface in machining process. Titanium alloy ring parts were pre-stretched at different condition by a lathe-specific pretension device respectively. By the cutting experimental, the cutting force ,chip formation and surface integrity indexes are compared and studied. The results show that in suitable compressive residual stress on machined surface are achieved by utilizing the prestressed cutting method ,meanwhile procedures of residual stress adjustment after machining could be omitted. Furthermore, the magnitude of compressive residual stress could be actively controlled by adjusting the magnitude of prestressed force in certain extent. And uniform saw-tooth chip are generated in prestressed cutting, meanwhile there’s no significant increment of cutting force. Prestressed cutting method could generate good surface integrity.

scholarly journals Research on Cutting Force and Surface Integrity of TC18 Titanium Alloy by Longitudinal Ultrasonic Vibration Assisted Milling

2021 ◽  
Author(s):  
Weibo Xie ◽  
Xikui Wang ◽  
Erbo Liu ◽  
Jian Wang ◽  
Xiaobin Tang ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Surface Integrity ◽  
Rotational Speed ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Surface Residual Stress ◽  
Deformation Layer ◽  
Vibration Milling

Abstract In order to study the influence of rotational speed and amplitude on the surface integrity, TC18 titanium alloy samples were milled by the process of conventional milling and longitudinal ultrasonic vibration assisted milling. The experimental data were obtained by dynamometer, thermometer, scanning electron microscope, X-ray diffractometer and three-dimensional surface topography instrument for observation and analysis. The results show that the rotational speed has a significant effect on the cutting force, cutting temperature, surface morphology and surface residual stress. Compared with ordinary milling, the surface micro-texture produced by ultrasonic vibration milling is more regular, , and with the increase of rotational speed, the influence of ultrasonic vibration on cutting force and cutting temperature decrease. There are adverse effects on surface roughness after ultrasonic vibration superposition. The influence of ultrasonic vibration on the surface residual compressive stress is also greatly reduced when the rotational speed is greater than 2400 rpm. In addition, a certain depth of plastic deformation layer can be formed under the surface of ultrasonic vibration machining, and the depth of deformation layer increases with the increase of vibration.

Model-based sensitivity analysis of machining-induced residual stress under minimum quantity lubrication

2015 ◽  
Vol 231 (9) ◽  
pp. 1528-1541 ◽  
Author(s):  
Xia Ji ◽  
Steven Y Liang
Keyword(s):  
Residual Stress ◽  
Sensitivity Analysis ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Mixture Ratio ◽  
Minimum Quantity

This article presents a sensitivity analysis of residual stress based on the verified residual stress prediction model. The machining-induced residual stress is developed as a function of cutting parameters, tool geometry, material properties, and lubrication conditions. Based on the residual stress predictive model, the main effects of the cutting force, cutting temperature, and residual stress are quantitatively analyzed through the cosine amplitude method. The parametric study is carried out to investigate the effects of minimum quantity lubrication parameters, cutting parameters, and tool geometry on the cutting performances. Results manifest that the cutting force and residual stress are more sensitive to the heat transfer coefficient and the depth of cut, while the cutting temperature is more sensitive to the cutting speed. Large maximum compressive residual stress is obtained under a lower flow rate of minimum quantity lubrication, small depth of cut, and the proper air–oil mixture ratio. This research can support the controlling and optimization of residual stress in industrial engineering by strategically adjusting the application parameters of minimum quantity lubrication.

The Effects of Machined Workpiece Surface Integrity on the Fatigue Life of TC21 Titanium Alloy

2012 ◽  
Vol 503-504 ◽  
pp. 382-389 ◽  
Author(s):  
Dong Xing Du ◽  
Dao Xin Liu ◽  
Yu Feng Sun ◽  
Jin Gang Tang ◽  
Xiao Hua Zhang
Keyword(s):  
Residual Stress ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Surface Integrity ◽  
Surface Profile ◽  
Fatigue Properties ◽  
Profile Measurement ◽  
Micro Hardness ◽  
Finish Turning ◽  
Rough Turning

In this paper, the influence of different machining methods (including rough turning, finish turning, and longitudinal polishing after finish turning) on rotating bending fatigue properties of TC21 which belonged to a new ultra high strength titanium alloy was studied. The influence of machining methods on surface integrity of TC21 titanium alloy was measured by using surface profile measurement, scanning electron microscopy, metallography microscope, micro-hardness instrument and X-ray diffraction residual stress analyzer. And fatigue fractography of specimens was further investigated. Then the mechanism of fatigue resistance which was affected by machining surface integrity was discussed. The results indicated that the fatigue life of finish turning and longitudinal polishing after finish turning was increased 3.96 times and 17.34 times compared with rough turning, respectively. The machining surface integrity had important influence on fatigue property of TC21 titanium alloy, which caused by the differences of surface roughness and texture as the dominant factors, and then the variation in surface micro-hardness, metallographic microstructure and the surface residual stress were not the main factors on three above-mentioned machining methods. By using longitudinal polishing after finish turning processing method for preparation of TC21 titanium alloy parts could ensure good surface integrity and excellent fatigue performance.

High-Quality End Milling of CFRP – Inclination Milling with High-Helix End Mill –

2016 ◽  
Vol 10 (3) ◽  
pp. 372-380 ◽  
Author(s):  
Akira Hosokawa ◽  
◽  
Naoya Hirose ◽  
Takashi Ueda ◽  
Tomohiro Koyano ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Integrity ◽  
Helix Angle ◽  
Surface Generation ◽  
End Mill ◽  
Side Milling ◽  
Pull Out ◽  
End Mills ◽  
Coated Carbide

Side milling tests of CFRP (carbon fiber reinforced plastics) containing thermosetting resin are carried out by TiAlN/AlCrN-coated, H2-free DLC (diamond-like carbon)-coated, and CVD diamond-coated carbide end mills without coolant. Two types of end mills having different helix angles of 30° and 60° are used. The film thickness and surface smoothness are varied for the DLC-coated end mills. The cutting characteristics are evaluated by tool wear and surface integrity (i.e., 3D profiles of the machined surface, generation of fluffing, delamination, and pull-out of the carbon fibers). The cutting force and tool flank temperature are also examined for the two types of CFRP composites and the helix angle of the end mill. “Inclination milling,”in which the end mill is tilted so that the resultant cutting force acts parallel to the work surface, is proposed as a novel technique to be used with a high-helix angle end mill. This unique approach enables the reduction of tool wear and improves the surface integrity of machined CFRP surfaces.

Surface Integrity and Fatigue Property of a High Speed Milled Titanium Alloy

2008 ◽  
Vol 53-54 ◽  
pp. 305-310 ◽  
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Work Hardening ◽  
High Speed ◽  
Cutting Speed ◽  
Fatigue Property ◽  
Machined Surface ◽  
Metallurgical Structure

Surface integrity has a great effect on the fatigue property of titanium alloy. The surface integrity and fatigue property of a high speed milled Ti-6.5Al-2Zr-1Mo-1V (TA15) titanium alloy were investigated in this research. The main objective of this paper is to study the influence of milling speed on the surface integraty and fatigue property of the machined part. The surface roughness, work hardening, metallurgical structure and residual stress of the machined surface were studied in a cutting speed range of from 50m/min to 300m/min. To verify the relationship between cutting speed and the surface integrity of machined surface, the fatigue property of titanium alloy specimens milled at four different cutting speeds ranging from 50 to 200m/min were compared at two stress levels. This research shows that the cutting speed has little effect on the work hardening, metallurgical structure and residual stress, but the surface roughness decreases with the increasing cutting speed. Therefore, increasing milling speed has a positive effect on the surface integrity and fatigue property of the machined surface.

Surface integrity generated with peripheral milling and the effect on low-cycle fatigue performance of aeronautic titanium alloy Ti-6Al-4V

2017 ◽  
Vol 122 (1248) ◽  
pp. 316-332 ◽  
Author(s):  
D. Yang ◽  
Z. Liu
Keyword(s):  
Residual Stress ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Stress Concentration ◽  
Surface Integrity ◽  
Stress Concentration Factor ◽  
Concentration Factor ◽  
Low Cycle Fatigue ◽  
Cycle Fatigue ◽  
Micro Hardness

ABSTRACTMachining-induced surface integrity has an important effect on reliability and service life of the components used in the aerospace industry where titanium alloy Ti-6Al-4V is widely applied. Characterisation of machining-induced surface integrity and revealing its effect on fatigue life are conducive to structural fatigue life optimisation design. In the present study, surface topography, residual stress, microstructure and micro-hardness were first characterised in peripheral milling of titanium alloy Ti-6Al-4V. Then, low-cycle fatigue performances of machined specimens were investigated on the basis of the tension-tension tests. Finally, the effects of surface integrity factors (stress concentration factor, residual stress and micro-hardness) on fatigue performances were discussed. Results show that stress concentration can reduce the fatigue life while increasing the residual compressive stress, and micro-hardness is beneficial to prolonging the fatigue life, but when the surface material of the specimen is subjected to plastic deformation due to yield, the residual stress on the surface is relaxed, and the effect on the fatigue performance is disappeared. Under the condition of residual stress relaxation, the stress concentration factor is the main factor to determine the low-cycle fatigue life of titanium alloy Ti-6Al-4V. While for the specimens with no residual stress relaxation, micro-hardness was the key factor to affect the fatigue life, followed by residual stress and stress concentration factor, respectively.

Experimental Investigation on the Surface Integrity of Titanium Alloy TC4 in Abrasive Belt Grinding

2013 ◽  
Vol 716 ◽  
pp. 185-190
Author(s):  
He Ping Wei ◽  
Yun Huang ◽  
Zhao Yang Liu
Keyword(s):  
Residual Stress ◽  
Experimental Investigation ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Cutting Speed ◽  
Velocity Range ◽  
Belt Grinding ◽  
Surface Residual Stress ◽  
Abrasive Belt ◽  
Surface Burn

This paper aimed at that titanium alloy grinding is easy to appear surface burn, crack, then carry out the titanium alloy TC4 abrasive belt grinding experiment, focus on the effect of grinding parameters on the titanium alloy TC4 surface integrity (surface roughness, microstructure and surface residual stress) . The results of the study show that the use of zircon corundum belt and cutting speed velocity range from 18 to 26 meter per second, the surface integrity of titanium alloy TC4 is better.

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