Prediction of Tool Wear Based on Cutting Forces When End Milling Titanium Alloy Ti-6Al-4V

2014 ◽  
Author(s):  
Cynthia Stanley ◽  
Durul Ulutan ◽  
Laine Mears
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Parameters ◽  
Resultant Force ◽  
Process Time ◽  
Force Output ◽  
Tool Failure ◽  
Tool Flank Wear

Research regarding tool wear in the machining of difficult materials is important because it is a significant indicator of process failure in terms of degradation of part quality, and the resulting high cost and increased process time. Prior researchers have investigated the effects of cutting parameters on tool wear and as a result, tool life has seen significant improvement. However, these studies are not concerned with tool flank wear during machining; they instead focus on tool flank wear after a certain amount of cutting distance. This study proposes a new method of predicting tool flank wear during machining that has the capability of suggesting tool failure without directly measuring the tool. For this purpose, a detailed set of experiments on end milling of titanium alloy Ti-6Al-4V was conducted and analyzed. Then, the resultant force output, which can be monitored during machining, was used to establish a predictive algorithm for tool flank wear. Using the increase in the resultant force as well as the total energy spent on the workpiece, it was shown that tool flank wear can be effectively predicted during machining and this can decrease the time spent on tool failure inspection and early tool change, increasing the throughput of the process.

Investigation of the Relationship Between Vibration Data and Tool Wear During End-Milling of Gamma-Prime Strengthened Alloys

2015 ◽  
Author(s):  
Vasileios Bardis ◽  
Farbod Akhavan Niaki ◽  
Durul Ulutan ◽  
Laine Mears
Keyword(s):  
Tool Wear ◽  
Prediction Models ◽  
Flank Wear ◽  
End Milling ◽  
Optical Microscope ◽  
Condition Based Maintenance ◽  
Tool Flank Wear ◽  
Vibration Data ◽  
Gamma Prime ◽  
The Relationship

Condition Based Maintenance (CBM) systems are crucial for today’s high accuracy machining of exotic materials. For reliable results, CBM systems need early and reliable warning based on prediction models that use multiple types of sensors. In this study, tool flank wear during end milling difficult-to-machine alloys was measured using an optical microscope. Then, vibration data collected with an accelerometer was investigated for its relationship to tool flank wear. The developed relationship between accelerometer output and tool flank wear was validated with further experiments. It was observed from frequency domain responses of these outputs that specific harmonics of the tool pass frequency were dominant, and tool flank wear can be related to the amplitude of these harmonics during machining. This way, it was shown that through accurate online prediction of tool wear, premature interruption of the process as well as machining with a worn tool can both be avoided, improving end-product quality as well as reducing machining costs.

Experimental Investigation on Tool Wear when End-Milling Inconel 718 with Coated Carbide Inserts

2011 ◽  
Vol 188 ◽  
pp. 410-415 ◽  
Author(s):  
Yuan Wei Wang ◽  
Jian Feng Li ◽  
Z.M. Li ◽  
Tong Chao Ding ◽  
Song Zhang
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Coated Carbide ◽  
Carbide Inserts

In this paper, some experiments were conducted to investigate tool wear when end-milling Inconel 718 with the TiAlN-TiN PVD coated carbide inserts. The worn tools were examined thoroughly under scanning electron microscope (SEM) with Energy Dispersive X-ray Spectroscopy and 3D digital microscope to expatiate tool wear morphologies and relevant mechanisms. The flank wear was uniformity in finishing milling process, and the average flank wear were selected as the criterion to study the effects of cutting parameters (cutting speed, feed per tooth, radial depth of cut, and axial depth of cut) on tool wear. Finally, the optimal combination of the cutting parameters for the desired tool life is obtained.

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.

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.

scholarly journals An experimental research on the machinability of a high temperature titanium alloy BTi-6431S in turning process

2018 ◽  
Vol 5 ◽  
pp. 12
Author(s):  
Yanfeng Gao ◽  
Yongbo Wu ◽  
Jianhua Xiao ◽  
Dong Lu
Keyword(s):  
Titanium Alloy ◽  
High Temperature ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Cutting Forces ◽  
Shear Bands ◽  
Cutting Parameters ◽  
Aircraft Manufacturing ◽  
Mechanical And Physical Properties ◽  
Alpha Titanium

Titanium alloys are extensively applied in the aircraft manufacturing due to their excellent mechanical and physical properties. At present, the α + β alloy Ti6Al4V is the most commonly used titanium alloy in the industry. However, the highest temperature that it can be used only up to 300 °C. BTi-6431S is one of the latest developed high temperature titanium alloys, which belongs to the near-α alloy group and has considerably high tensile strength at 650 °C. This paper investigates the machinability of BTi-6431S in the terms of cutting forces, chip formation and tool wear. The experiments are carried out in a range of cutting parameters and the results had been investigated and analyzed. The investigation shows that: (1) the specific cutting forces in the machining of BTi-6431S alloy are higher than in the machining of Ti6Al4V alloy; (2) the regular saw-tooth chips more easily formed and the shear bands are narrower in the machining of BTi-6431S; (3) SEM and EDS observations of the worn tools indicate that more cobalt elements diffuse into the workpiece from tool inserts during machining of BTi-6431S alloy, which significantly aggravates tool wear rate. The experimental results indicate that the machinability of BTi-6431S near alpha titanium alloy is significantly lower than Ti-6Al-4V alloy.

scholarly journals Online Tool Wear Monitoring by the Analysis of Cutting Forces in Transient State for Dry Machining of Ti6Al4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 1014 ◽  
Author(s):  
Sánchez Hernández ◽  
Trujillo Vilches ◽  
Bermudo Gamboa ◽  
Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Transient State ◽  
Cutting Parameters ◽  
Dry Machining ◽  
Crater Wear ◽  
Force Amplitude

In this work, the analysis of the cutting speed and feed rate influence on tool wear and cutting forces in Ti6Al4V alloy dry machining is presented. The study has been focused on the machining in a transient state. The tool wear mechanisms, tool wear intensity and cutting forces evolution have been analyzed as a function of the cutting parameters. Experimental results show that the main cutting force amplitude exhibits a general trend to increase with both cutting parameters. Crater wear was more evident at high cutting speeds, whereas flank wear was present on the whole interval of the cutting parameters analyzed. Furthermore, the cutting speed shows a slightly higher influence on crater wear and the feed rate shows a higher influence on flank wear. Finally, several experimental parametric models have been obtained. These models allow predicting the evolution of crater and flank tool wear, as well as the cutting forces, as a function of the cutting parameters. Additionally, a model that allows monitoring the tool wear on the machining transient state as a function of the main cutting force amplitude has been developed.

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.

Analysis of Tool Wear: Part II: Applications of Flank Wear Models

1970 ◽  
Vol 92 (1) ◽  
pp. 109-114 ◽  
Author(s):  
A. Bhattacharyya ◽  
A. Ghosh ◽  
Inyong Ham
Keyword(s):  
Tool Wear ◽  
Critical Points ◽  
Quantitative Assessment ◽  
Inflection Point ◽  
Flank Wear ◽  
Cemented Carbides ◽  
Temperature Sensitive ◽  
Tool Failure ◽  
Cutting Speeds ◽  
Asme Paper

For machining with cemented carbides and ceramics, a quantitative assessment of tool failure at the flank for establishing “limit criterion” is necessary. The arbitrarily chosen flank wear limit for all cutting speeds is not valid at higher cutting speeds because of the earlier appearance of the “inflection point” which is often taken as criterion of flank-failure. In this paper, proceeding from the basic physical model of flank wear described in Part I of the paper (ASME Paper No. 68—WA/Prod-5), tool-life relations in the form of Taylor’s equations have been theoretically developed, the parameters of which have been compared with, experimental results. Further, the critical points of inflexion where the flank-wear characteristic enters temperature sensitive region resulting in accelerated wear have been uniquely defined. The location of these critical points have also been verified experimentally.

An Approach to Improve Cutting Performance in Micromilling of Titanium Alloy

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Yunn-Shiuan Liao ◽  
Tsung-Hsien Li ◽  
Yi-Chen Liu
Keyword(s):  
Carbon Dioxide ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Liquid Carbon ◽  
Dry Cutting ◽  
Machined Surface ◽  
Liquid Carbon Dioxide

Abstract Application of liquid carbon dioxide to improve cutting performance in micro-end milling of Ti-6Al-4V titanium alloy was proposed in this study. It was found that the machined roughness decreased with the cutting speed as observed in the conventional cutting, when a 0.5 mm diameter end milling cutter was used in dry cutting. But, the tiny and shattered chips produced by the use of 0.3 mm diameter cutter could adhere on the machined surface and deteriorate surface finish, if the cutting speed was higher than 40 m/min. Cutting temperature was effectively decreased by applying liquid carbon dioxide during micromilling, which in turn reduced the amount of chips adhering on the machined surface and lowered flank wear. The surface roughness Ra at a cutting speed of 70 m/min was improved from 0.09 μm under dry cutting to 0.04 μm under the liquid carbon dioxide assisted cutting condition. And there were no flank wear and very few burrs left on the machined surface for the condition used in the experiment. The height of the burrs was only 25% of that under dry cutting. More, minimum quantity lubrication (MQL) was proposed to be applied together with the liquid carbon dioxide to enhance lubrication effect. It was noted that the machined surface roughness was further decreased by 15% as compared with that when the liquid carbon dioxide was applied alone. The height of burrs was reduced from 32 μm to 16 μm.

Research on Wear Property of Tool Flank by Dry Cutting of Austempering Ductile Iron

2011 ◽  
Vol 188 ◽  
pp. 38-42
Author(s):  
Dong Dong Wan ◽  
Xu Hong Guo ◽  
Chi Hong Wang
Keyword(s):  
Cutting Tool ◽  
Flank Wear ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Wear Property ◽  
Dry Cutting ◽  
Quenching Temperature ◽  
Tool Flank Wear ◽  
Heat Treated

Three different cutting tools (ceramics CC6050, cubic boron nitride CB7025, carbide GC2025) were used for dry cutting of 3 groups of ADI which were heat-treated separately under different quenching temperatures. With the unified cutting parameters, the wear of tool flank of each cutter was studied and the main influencing factors of the wear were analyzed. Results showed that when the cutting parameters ap =0.2mm, f =0.16mm/r, vc =108m/min and the cutting tool was determined, the higher the quenching temperature was the lower the hardness of the test bars were and the tool flank wear was less; When the quenching temperature was determined, the more the produced BUE (build up edge) of the cutting tool was the less the tool flank wear was.

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