Study of Droplet Spray Behavior of an Atomization-Based Cutting Fluid Spray System for Machining Titanium Alloys

2014 ◽  
Vol 136 (2) ◽  
Author(s):  
Chandra Nath ◽  
Shiv G. Kapoor ◽  
Anil K. Srivastava ◽  
Jon Iverson
Keyword(s):  
Titanium Alloys ◽  
Tool Life ◽  
Droplet Velocity ◽  
Cutting Fluid ◽  
Gas Velocity ◽  
Spray Distance ◽  
Droplet Entrainment ◽  
Spray System ◽  
Flow Development ◽  
Droplet Spray

The atomization-based cutting fluid (ACF) spray system has been found to be effective for improving the tool life and overall productivity during the machining of titanium alloys like Ti–6Al–4 V. The aim of this research is to study droplet spray characteristics of an ACF spray system including droplet entrainment zone (e.g., angle and distance) and droplet-gas co-flow development regions with respect to three ACF spray parameters, viz., droplet and gas velocities, and spray distance. ACF spray experiments are performed by varying droplet and gas velocities. Machining experiments are performed in order to understand the effect of the droplet spray behavior on the machining performance, viz., tool life/wear, and surface roughness during turning of a titanium alloy, Ti–6Al–4 V. The flow development behavior with respect to the spray distance is studied by modeling the droplets entrainment mechanism. The model is validated by the ACF spray experiments. Experiments and the modeling of flow development behavior reveal that a higher droplet velocity and a smaller gas velocity result in smaller droplet entrainment angle leading to a gradual and early development of the co-flow, and a better distribution of the droplets across the jet flare. Machining experiments also show that a higher droplet velocity, a lower gas velocity and a longer spray distance significantly improve tool life and surface finish.

scholarly journals Droplet Spray Behavior of an Atomization-Based Cutting Fluid (ACF) System for Machining of Titanium Alloys

2012 ◽  
Author(s):  
Chandra Nath ◽  
Shiv G. Kapoor ◽  
Anil K. Srivastava ◽  
Jon Iverson
Keyword(s):  
Tool Life ◽  
Droplet Velocity ◽  
Cutting Fluid ◽  
Spray Parameters ◽  
Gas Velocity ◽  
Spray Distance ◽  
Droplet Entrainment ◽  
Spray System ◽  
Flow Development ◽  
Droplet Spray

The aim of this research is to study droplet spray characteristics of an atomization-based cutting fluid (ACF) spray system including droplet entrainment angle and flow development regions with respect to three ACF spray parameters, viz., droplet and gas velocities, and spray distance. ACF spray experiments are performed by varying droplet and gas velocities. The flow development behavior is studied by modeling the droplets entrainment mechanism, and the density and distribution of the droplets across the jet flare. Machining experiments are also performed in order to understand the effect of the droplet spray behavior on the machining performances, viz., tool life/wear, and surface roughness during turning of a titanium alloy, Ti-6Al-4V. Experiments and the modeling of flow development behavior reveal that a higher droplet velocity and a smaller gas velocity result in smaller droplet entrainment angle leading to a gradual and early development of the co-flow with a smaller density and a better distribution of the droplet across the jet flare. Machining experiments also show that a higher droplet velocity, a lower gas velocity and a longer spray distance significantly improve the machining performances such as tool life and wear, and surface finish.

High Pressure Coolant Application in Milling Titanium

2009 ◽  
Vol 618-619 ◽  
pp. 89-92 ◽  
Author(s):  
Suresh Palanisamy ◽  
Dean Townsend ◽  
M. Scherrer ◽  
Robert Andrews ◽  
Matthew S. Dargusch
Keyword(s):  
High Pressure ◽  
Titanium Alloys ◽  
Tool Life ◽  
Surface Finish ◽  
Cutting Fluid ◽  
Cutting Zone ◽  
High Pressure Coolant

Removal of heat from the cutting zone is critical when machining titanium. The application of high pressure coolant during turning of titanium results in longer tool life and better surface finish. In this paper, the effect of the application of cutting fluid at high pressure during the milling of titanium alloys is presented.

scholarly journals Formulation of Sustainable Water-Based Cutting Fluids with Polyol Esters for Machining Titanium Alloys

Metals ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 773
Author(s):  
Elisabet Benedicto ◽  
Eva María Rubio ◽  
Laurent Aubouy ◽  
María Ana Sáenz-Nuño
Keyword(s):  
Molecular Structure ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Film Formation ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Lubricating Film ◽  
Wear Protection ◽  
Oil In Water ◽  
Polyol Esters

The machinability of titanium alloys still represents a demanding challenge and the development of new clean technologies to lubricate and cool is greatly needed. As a sustainable alternative to mineral oil, esters have shown excellent performance during machining. Herein, the aim of this work is to investigate the influence of esters’ molecular structure in oil-in-water emulsions and their interaction with the surface to form a lubricating film, thus improving the efficiency of the cutting fluid. The lubricity performance and tool wear protection are studied through film formation analysis and the tapping process on Ti6Al4V. The results show that the lubricity performance is improved by increasing the formation of the organic film on the metal surface, which depends on the ester’s molecular structure and its ability to adsorb on the surface against other surface-active compounds. Among the cutting fluids, noteworthy results are obtained using trimethylolpropane trioleate, which increases the lubricating film formation (containing 62% ester), thus improving the lubricity by up to 12% and reducing the torque increase due to tool wear by 26.8%. This work could be very useful for fields where often use difficult-to-machine materials—such as Ti6Al4V or γ-TiAl – which require large amounts of cutting fluids, since the formulation developed will allow the processes to be more efficient and sustainable.

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%.

A Thermal Model to Predict Tool Temperature in Machining of Ti-6Al-4V Alloy With an Atomization-Based Cutting Fluid Spray System

2016 ◽  
Author(s):  
Asif Tanveer ◽  
Deepak Marla ◽  
Shiv G. Kapoor
Keyword(s):  
Heat Transfer ◽  
Interaction Model ◽  
Spray Cooling ◽  
Droplet Surface ◽  
Cutting Fluid ◽  
Design Parameters ◽  
Transfer Model ◽  
Tool Temperature ◽  
Spray System ◽  
Heat Transfer Phenomenon

In this study a heat transfer model of machining of Ti-6Al-4V under the application of atomization-based cutting fluid spray coolant is developed to predict the temperature of the cutting tool. Owing to high tool temperature involved in machining of Ti-6Al-4V, the model considers film boiling as the major heat transfer phenomenon. In addition, the design parameters of the spray for effective cooling during machining are derived based on droplet-surface interaction model. Machining experiments are conducted and the temperatures are recorded using the inserted thermocouple technique. The experimental data are compared with the model predictions. The temperature field obtained is comparable to the experimental results, confirming that the model predicts tool temperature during machining with ACF spray cooling satisfactorily.

Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

2018 ◽  
Author(s):  
Kai Guo ◽  
Bin Yang ◽  
Jie Sun ◽  
Vinothkumar Sivalingam
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Wear Model ◽  
Wear Process ◽  
Coated Carbide Tool ◽  
Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

Tool Life Analysis when Turning Ti-6Al-4V Using Vegetable Oil-Based Cutting Fluid

2017 ◽  
Vol 882 ◽  
pp. 36-40
Author(s):  
Salah Gariani ◽  
Islam Shyha ◽  
Connor Jackson ◽  
Fawad Inam
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Vegetable Oil ◽  
Flank Wear ◽  
Cutting Speed ◽  
Fractional Factorial ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Fluid Concentration

This paper details experimental results when turning Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. The effects of coolant concentration and working conditions on tool flank wear and tool life were evaluated. L27 fractional factorial Taguchi array was employed. Tool wear (VBB) ranged between 28.8 and 110 µm. The study concluded that a combination of VOs based cutting fluid concentration (10%), low cutting speed (58 m/min), feed rate (0.1mm/rev) and depth of cut (0.75mm) is necessary to minimise VBB. Additionally, it is noted that tool wear was significantly affected by cutting speeds. ANOVA results showed that the cutting fluid concentration is statistically insignificant on tool flank wear. A notable increase in tool life (TL) was recorded when a lower cutting speed was used.

Highlights of the DARPA Advanced Machining Research Program

1985 ◽  
Vol 107 (4) ◽  
pp. 325-335 ◽  
Author(s):  
R. Komanduri ◽  
D. G. Flom ◽  
M. Lee
Keyword(s):  
Thermal Properties ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Research Program ◽  
High Speed ◽  
Metal Removal ◽  
High Speed Machining ◽  
Advanced Machining ◽  
Nickel Base

Results of a four-year Advanced Machining Research Program (AMRP) to provide a science base for faster metal removal through high-speed machining (HSM), high-throughput machining (HTM) and laser-assisted machining (LAM) are presented. Emphasis was placed on turning and milling of aluminum-, nickel-base-, titanium-, and ferrous alloys. Experimental cutting speeds ranged from 0.0013 smm (0.004 sfpm) to 24,500 smm (80,000 sfpm). Chip formation in HSM is found to be associated with the formation of either a continuous, ribbon-like chip or a segmental (or shear-localized) chip. The former is favored by good thermal properties, low hardness, and fcc/bcc crystal structures, e.g., aluminum alloys and soft carbon steels, while the latter is favored by poor thermal properties, hcp structure, and high hardness, e.g., titanium alloys, nickel base superalloys, and hardened alloy steels. Mathematical models were developed to describe the primary features of chip formation in HSM. At ultra-high speed machining (UHSM) speeds, chip type does not change with speed nor does tool wear. However, at even moderately high speeds, tool wear is still the limiting factor when machining titanium alloys, superalloys, and special steels. Tool life and productivity can be increased significantly for special applications using two novel cutting tool concepts – ledge and rotary. With ledge inserts, titanium alloys can be machined (turning and face milling) five times faster than conventional, with long tool life (~ 30 min) and cost savings up to 78 percent. A stiffened rotary tool has yielded a tool life improvement of twenty times in turning Inconel 718 and about six times when machining titanium 6A1-4V. Significantly increased metal removal rates (up to 50 in.3/min on Inconel 718 and Ti 6A1-4V) have been achieved on a rigid, high-power precision lathe. Continuous wave CO2 LAM, though conceptually feasible, limits the opportunities to manufacture DOD components due to poor adsorption (~ 10 percent) together with high capital equipment and operating costs. Pulse LAM shows greater promise, especially if new laser source concepts such as face pump lasers are considered. Economic modeling has enabled assessment of HSM and LAM developments. Aluminum HSM has been demonstrated in a production environment and substantial payoffs are indicated in airframe applications.

scholarly journals Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771061 ◽  
Author(s):  
Duc Tran Minh ◽  
Long Tran The ◽  
Ngoc Tran Bao
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Minimum Quantity Lubrication ◽  
High Hardness ◽  
Cemented Carbide ◽  
Cutting Fluid ◽  
Hard Milling ◽  
Minimum Quantity ◽  
Coated Carbide ◽  
Lubrication Conditions

In this article, an attempt has been made to explore the potential performance of Al2O3 nanoparticle–based cutting fluid in hard milling of hardened 60Si2Mn steel (50-52 HRC) under different minimum quantity lubrication conditions. The comparison of hard milling under minimum quantity lubrication conditions is done between pure cutting fluids and nanofluids (in terms of surface roughness, cutting force, tool wear, and tool life). Hard milling under minimum quantity lubrication conditions with nanofluid Al2O3 of 0.5% volume has shown superior results. The improvement in tool life almost 177%–230% (depending on the type of nanofluid) and the reduction in surface roughness and cutting forces almost 35%–60% have been observed under minimum quantity lubrication with Al2O3 nanofluids due to better tribological behavior as well as cooling and lubricating effects. The most outstanding result is that the uncoated cemented carbide insert can be effectively used in machining high-hardness steels (>50 HRC) while maintaining long tool life and good surface integrity (Ra = 0.08–0.35 µm; Rz = 0.5–2.0 µm, equivalent to finish grinding) rather than using the costlier tools like coated carbide, ceramic, and (P)CBN. Therefore, using hard nanoparticle–reinforced cutting fluid under minimum quantity lubrication conditions in practical manufacturing becomes very promising.

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.

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