Cryogenic Machining of Titanium Ti-5553 Alloy

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Yusuf Kaynak ◽  
Armin Gharibi
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Machining Process ◽  
Dry Machining ◽  
Cryogenic Machining ◽  
Machining Performance ◽  
Wide Range ◽  
New Generation

Titanium alloy Ti-5Al-5V-3Cr-0.5Fe (Ti-5553) is a new generation of near-beta titanium alloy that is commonly used in the aerospace industry. Machining is one of the manufacturing methods to produce parts that are made of this near-beta alloy. This study presents the machining performance of new generation near-beta alloys, namely, Ti-5553, by focusing on a high-speed cutting process under cryogenic cooling conditions and dry machining. The machining experiments were conducted under a wide range of cutting speeds, including high speeds that used liquid nitrogen (LN2) and carbon dioxide (CO2) as cryogenic coolants. The experimental data on the cutting temperature, tool wear, force components, chip breakability, dimensional accuracy, and surface integrity characteristics are presented and were analyzed to evaluate the machining process of this alloy and resulting surface characteristics. This study shows that cryogenic machining improved the machining performance of the Ti-5553 alloy by substantially reducing the tool wear, cutting temperature, and dimensional deviation of the machined parts. The cryogenic machining also produced shorter chips as compared to dry machining.

FE Simulation of Cryogenic Assisted Machining of Ti Alloy (Ti6AI4V)

2015 ◽  
Author(s):  
Vivek Bajpai ◽  
Ineon Lee ◽  
Hyung Wook Park
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Cutting Forces ◽  
Turbine Blades ◽  
Chip Morphology ◽  
Machining Process ◽  
Burr Formation ◽  
Dry Machining ◽  
Cryogenic Machining ◽  
Ti Alloys

Titanium alloys are well-known material because of the excellent mechanical/chemical properties, corrosion resistance and light weight. These alloys are widely used in the high performance applications such as; aerospace, aviation, bio-implants, turbine blades etc. Machining is commonly used to create products out of Ti alloys. Despite of good material properties, Ti alloys have low thermal conductivity, poor machinability, burr formation, high machining temperature, tool wear and poor machinability. The tool wear and high machining temperature can be controlled through coolant. Cryogenic fluid (liquid nitrogen) is a common material used as coolant in various machining process. The current work is focused on the modeling of cryogenic machining on titanium alloy (Ti6Al4V). Dry machining and cryogenic machining processes are modeled for the chip formation and cutting forces in 2D. Experimental works have been performed to validate the model based on the cutting forces and chip morphology. It is showed that the model is capturing the process, evident by the cutting forces and the chip morphology. The error in prediction is limited to 18%. Model showed that the cutting forces are increasing in cryogenic machining due to the increased strength of the workpiece at low temperature. Chip formation is well captured by the current model. Shear band width have been captured in dry machining. Chip curling has been captured at dry and cryogenic machining. It is expected that the model can further useful in the selection of cryogenic process parameter, such as, flow rate, application techniques etc.

Acoustic Emission-Based Tool Condition Classification in a Precision High-Speed Machining of Titanium Alloy: A Machine Learning Approach

2018 ◽  
Vol 17 (03) ◽  
pp. 1850017 ◽  
Author(s):  
P. Krishnakumar ◽  
K. Rameshkumar ◽  
K. I. Ramachandran
Keyword(s):  
Acoustic Emission ◽  
Titanium Alloy ◽  
Tool Wear ◽  
High Speed ◽  
Machining Process ◽  
Support Vector ◽  
Tool Condition ◽  
Wide Range ◽  
Cutting Zone ◽  
Tungsten Carbide Tool

Mechanical and chemical properties of titanium alloy have led to its wide range of applications in aerospace and biomedical industries. The heat generation and its transfer from the cutting zone are critical in machining of titanium alloys. The process of transferring heat from the primary cutting zone is difficult due to poor thermal conductivity of titanium alloy, and it will lead to rapid tool wear and poor surface finish. An effective tool monitoring system is essential to predict such variations during machining process. In this study, using a high-speed precision mill, experiments are conducted under optimum cutting conditions with an objective of maximizing the life of tungsten carbide tool. Tool wear profile is established and tool conditions are arrived on the basis of the surface roughness. Acoustic emission (AE) signals are captured using an AE sensor during machining of titanium alloy. Statistical features are extracted in time and frequency domain. Features that contain rich information about the tool conditions are selected using J48 decision tree (DT) algorithm. Tool condition classification abilities of DT and support vector machines are studied in time and frequency domains.

Dry Machining of Inconel 825 Superalloys

2021 ◽  
Vol 11 (4) ◽  
pp. 26-39
Author(s):  
Kshitij Pandey ◽  
Saurav Datta
Keyword(s):  
Tool Wear ◽  
Surface Morphology ◽  
Cutting Force ◽  
Carbide Tool ◽  
Dry Machining ◽  
Machining Performance ◽  
Force Magnitude ◽  
Wear Pattern ◽  
Inconel 825

The present work investigates application feasibility of PVD TiN/TiCN/TiN coated cermet and CVD Al2O3/TiCN coated SiAlON for dry machining of Inconel 825 superalloy. Machining performance is interpreted through cutting force magnitude, tool-tip temperature, and mechanisms of tool wear. Results are compared to that of CVD multi-layer TiN/TiCN/Al2O3/TiN coated WC-Co tool. It is evidenced that SiAlON tool generates lower cutting force but experiences higher tool-tip temperature than other two counterparts. Apart from abrasion and adhesion, carbide tool witnesses coating peeling and ploughing. In contrast, SiAlON tool suffers from inexorable chipping and notching. Wear pattern of cermet tool seems less severe than carbide and SiAlON. Chip's underside surface morphology appears relatively better in case of cermet tool.

Experimental Investigation of Mechanical-Thermal Characteristics in High Efficiency Turning Titanium Alloy Ti6Al4V

2016 ◽  
Vol 836-837 ◽  
pp. 20-28
Author(s):  
Li Min Shi ◽  
Cheng Yang ◽  
Qi Jun Li
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Efficiency ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Thermal Characteristics ◽  
Tool Failure ◽  
Minimal Quantity Lubrication ◽  
Titanium Alloy Ti6al4v

Titanium alloy Ti6Al4V has poor machinability, which leads to high unit cutting force and cutting temperature, rapid tool failure. In this study, the effect of the cutting speed, feed rate and cooling condition on cutting force and cutting temperature is critically analysed by turning experiment. At the same time, the relationship is established among tool wear, cutting force and cutting temperature. This investigation has shown that cutting speed is the decisive factor which increasing cutting force and cutting temperature. In the process of turning, tool wear results in high amounts of heat and mechanical stress, which leads to serious tool wear. The Minimal Quantity Lubrication reduces the frictional condition at the chip-tool, decreases cutting force and cutting temperature, and delays the tool failure.

ASSESSING THE TRIBOLOGICAL PROPERTIES OF VEGETABLE OIL EMULSIONS AND MACHINING PARAMETER OPTIMIZATION USING RESPONSE SURFACE METHODOLOGY

2021 ◽  
Author(s):  
D. K. KARUPANNASAMY ◽  
M. SAMBATHKUMAR ◽  
R. GUKENDRAN ◽  
K. S. K. SASIKUMAR ◽  
N. BAASKARAN ◽  
...  
Keyword(s):  
Response Surface Methodology ◽  
Tool Wear ◽  
Response Surface ◽  
Surface Finish ◽  
Castor Oil ◽  
Mineral Oil ◽  
Machining Process ◽  
Neem Oil ◽  
Machining Performance ◽  
Oil Emulsions

Bio-degradable lubricants are the need for industries to promote eco-friendly manufacturing process and protect the workers from health hazards. In this paper, the use of oil–water emulsions from the bio-substitute oils have been formulated and its process parameter on a machining process are optimized using response surface methodology. The emulsions are prepared from the vegetable oils such as castor, mahua, palm and neem oil with polysorbate as emulsifying agent. The friction and wear characteristics are studied with a standard pin on disc tribometer for all the emulsions prepared with the base oils namely castor, mahua and palm oil. From the tribological characterization tests, the castor oil emulsions have shown better performance and stability in comparison to other oils. Hence, castor oil emulsions have been tested for its machining performance studies against a conventional mineral oil emulsion in a turning process. Further, an emulsion based on castor oil and neem oil have been tested for tool wear to utilize the antimicrobial properties of neem oil for reducing the bio fouling effects. The machining performance is indicated based on the surface finish and tool wear. Response surface methodology have been used for optimization of the machining parameters, such as cutting velocity, feed rate and depth of cut to achieve an optimal surface finish for a maximum material removal rate. The results show that the castor oil based emulsion can be used as an excellent alternative for mineral oil emulsions.

EFFECT OF CUTTING PARAMETERS ON CUTTING ZONE IN CRYOGENIC HIGH SPEED MILLING OF INCONEL 718 ALLOY

2015 ◽  
Vol 77 (27) ◽  
Author(s):  
A. H. Musfirah ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Cutting Condition ◽  
Dry Machining ◽  
Part Quality ◽  
Cutting Zone ◽  
Coated Carbide

In tribology phenomenon, surface roughness has become one of the most important factors that contributed to the evaluation of part quality during machining operation. In order to understand the behavior of cryogenic cooling assistance in machining Inconel 718, this paper aims to provide better understanding of tribological characterization of liquid nitrogen near the cutting zone of this material in ball end milling process. Experiments were performed using a multi-layer TiAlN/AlCrN-coated carbide inserts under cryogenic and dry cutting condition. A transient milling simulation model using Third Wave Advantedge has been done in order to gain in-depth understanding of the thermomechanical aspects of machining and their influence on resulted part quality. The cryogenic results of the cutting temperature, cutting forces and surface roughness of the ball nose cutting tool have been compared with those of dry machining. Finally, experimental results proved that cryogenic implementation can  decrease the amount of heat transferred to the tool up to almost 70% and improve the surface roughness to a maximum of 31% when compared with dry machining. Furthermore, the microstructure of machined workpiece revealed that cryogenic cooling also can reduce a plastic deformation at the cutting surface as compared with the dry machining. 

Secondary Machining Characteristics of Additive Manufactured Titanium Alloy Ti-6Al-4V

2018 ◽  
Vol 779 ◽  
pp. 149-152 ◽  
Author(s):  
Ashwin Polishetty ◽  
Basil Raju ◽  
Guy Littlefair
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Wide Range ◽  
Secondary Operations ◽  
Cylindrical Workpiece ◽  
Almost All

Titanium alloy, Ti-6Al-4V is a popular alloy used in wide range of design applications mostly in aerospace and biomedical industry due to its advantageous material properties. This research is based on threading operation in a cylindrical workpiece of Ti-6Al-4V additive manufactured by Selective Laser Melting (SLM) technique. Secondary machining is described as the operations that are performed on the workpiece after a primary machining in order to achieve a required finish and form. Common secondary operations after drilling includes threading, reaming and knurling. Threading is a significant machining process in almost all applications of Titanium alloys. The development of an efficient threading process for Titanium alloys and enhancing existing methods may lead to a wider application of additive manufactured Titanium alloys. The aim of this research is to find out favorable threading conditions for Titanium alloy Ti-6Al-4V to obtain better machinability. Threads are tapped into the workpiece using variable machining parameters such as spindle speed and depth of cut. Statistical data are collected and analyzed by qualitative and quantitative evaluation of the threads. The outputs under consideration to evaluate efficiency of the secondary machining include surface texture (roughness (Ra)), dimensional accuracy (thread geometry) and power required (cutting force).

Control of Machining Process for Titanium Alloy Based on Green Cooling and Lubricating Technology

2012 ◽  
Vol 580 ◽  
pp. 7-11
Author(s):  
Yue Zhang ◽  
Li Han ◽  
You Jun Zhang ◽  
Xi Chuan Zhang
Keyword(s):  
Titanium Alloy ◽  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Small Diameter ◽  
Machining Process ◽  
Machined Surface ◽  
Cutting Zone ◽  
Cutting Experiments ◽  
Special Control

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. The cutting experiments are carried out based on green cooling and lubricating technology. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface. And it can help to chip forming and breaking. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy.

Performance Evaluation of Liquid Nitrogen as Coolant in Turning of Al/SiC Metal Matrix Composites (AMMC)

2014 ◽  
Vol 893 ◽  
pp. 341-345 ◽  
Author(s):  
Vadivel Muthuraman ◽  
Murugesan Pradeepkumar
Keyword(s):  
Cutting Force ◽  
Liquid Nitrogen ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cryogenic Liquid ◽  
Matrix Composites ◽  
Performance Parameters ◽  
Cryogenic Machining ◽  
Machining Performance ◽  
Better Than

This paper presents the results of an experimental investigation on the turning of Al/SiC (LM-13) composite using Cryogenic Liquid Nitrogen (LN2) as coolant. The influence of machining performance parameters such as cutting force, cutting temperature and surface finish were investigated under wet and cryogenic machining. The results proved that the application of cryogenic LN2coolant reduced the cutting temperature and the cutting force for about 19 to 30% and 24 to 35% respectively. The surface finish of the machined part is about 10 to 23% better than in the conventional coolant. Thus it was proved that the application of cryogenic coolants reduced the cutting force and temperature which resulted in an appreciable improvement in surface finish in machining of Al/SiC MMC.

Sign in / Sign up

Export Citation Format

Share Document