scholarly journals Fundamental Investigation into Tool Wear and Surface Quality in High-Speed Machining of Ti6Al4V Alloy

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7128
Author(s):  
Adel T. Abbas ◽  
Essam A. Al Bahkali ◽  
Saeed M. Alqahtani ◽  
Elshaimaa Abdelnasser ◽  
Noha Naeim ◽  
...  
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Speed ◽  
Ti6al4v Alloy ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Crater Wear ◽  
Machined Surface ◽  
Cutting Length

This paper reports a fundamental investigation consisting of systematic trials into the response of Ti6Al4V alloy to high-speed machining using carbide inserts. It is a useful extension to work previously published, and aims at assessing the impact of the process parameters, depth of cut, cutting speed and feed rate in addition to cutting length, and their interrelations, on observed crater and flank wear and roughness of the machined surface. The results showed that abrasion was the most important flank wear mechanism at high speed. It also showed that increased cutting length accelerated crater wear more than exhibited flank wear and had considerable effect on surface roughness. In particular, crater wear increased by over 150% (on average), and flank wear increased by 40% (on average) when increasing cutting length from 40 to 120 mm. However, cutting the same length increased surface roughness by 50%, which helps explain how progression of tool wear leads to deteriorated surface quality. ANOVA was used to perform statistical analyses of the measured data and revealed that cutting length and depth of cut had the greatest effect on both crater and flank wear of the cutting tool. These results confirm that high-speed machining of Ti6Al4V alloy is a reliable process, with cutting speed identified as having a relatively small influence on the tool wear and resultant roughness of the machined surface relative to other parameters.

scholarly journals Flank Wear Modelling in High Speed Hard Milling of AISI D2 Steel

2020 ◽  
Vol 5 (2) ◽  
pp. 50-54
Author(s):  
Muataz Al Hazza ◽  
Khadijah Muhammad
Keyword(s):  
Statistical Analysis ◽  
Wear Rate ◽  
Taguchi Method ◽  
Feed Rate ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Aisi D2

High speed machining has many advantages in reducing time to the market by increasing the material removal rate. However, final surface quality is one of the main challenges for manufacturers in high speed machining due to the increasing of flank wear rate. In high speed machining, the cutting zone is under high pressure associated with high temperature that lead to increasing of the flank wear rate in which affect the final quality of the machined surface. Therefore, one of the main concerns to the manufacturer is to predict the flank wear to estimate and predict the surface roughness as one of the main outputs of the machining processes. The aim of this study is to determine experimentally the optimum cutting parameters: depth of cut, cutting speed (Vc) and feed rate (f) that maintaining low flank wear (Vb). Taguchi method has been applied in this experiment. The Taguchi method has been universally used in engineering analysis.  JMP statistical analysis software is used to analyse statically the development of flank wear rate during high speed milling of hardened steel AISI D2 to 60 HRD. The experiment was conducted in the following boundaries: cutting speed 200-400 m/min, feed rate of 0.01-0.05 mm/tooth and depth of cut of 0.1-0.2 mm. Analysis of variance ANOVA was conducted as one of important tool for statistical analysis. The result showed that cutting speed is the most influential input factors with 70.04% contribution on flank wear.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

Study of High-Speed Machining Parameters on Nickel-Based Alloy GH2132

2011 ◽  
Vol 189-193 ◽  
pp. 3142-3147 ◽  
Author(s):  
Dong Qiang Gao ◽  
Zhong Yan Li ◽  
Zhi Yun Mao
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Nickel Based Alloy

A model of stress and temperature field is established on nickel-based alloy cutting by finite element modeling and dynamic numerical simulating, and then combining high-speed machining test and orthogonality analysis method, the influence law of cutting parameters on the cutting force and tool wear has been researched, and the tool life and cutting force prediction model based on cutting parameters has been obtained. Finally, by genetic algorithm method cutting parameters are selected reasonably and optimized. The result shows that the bonding wear is main tool wear, and the influence of cutting speed on cutting force is smaller than feed per tooth and axial depth of cut.

A Fracture Mechanics Approach to the Prediction of Tool Wear in Dry High Speed Machining of Aluminum Cast Alloys: Part 2 — Model Calibration and Verification

Tribology ◽  
2005 ◽  
Author(s):  
Alexander Bardetsky ◽  
Helmi Attia ◽  
Mohamed Elbestawi
Keyword(s):  
Fracture Mechanics ◽  
Tool Wear ◽  
Model Calibration ◽  
High Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Wear Model ◽  
Wide Range ◽  
Cast Alloys

Experimental study has been carried out to establish the effect of cutting conditions (speed, feed, and depth of cut) on the cutting forces and time variation of carbide tool wear data in high-speed machining (face milling) of Al-Si cast alloys that are commonly used in the automotive industry. The experimental setup and force measurement system are described. The test results are used to calibrate and validate the fracture mechanics-based tool wear model developed in Part 1 of this work. The model calibration is conducted for two combinations of cutting speed and a feed rate, which represent a lower and upper limit of the range of cutting conditions. The calibrated model is then validated for a wide range of cutting conditions. This validation is performed by comparing the experimental tool wear data with the tool wear predicted by calibrated cutting tool wear model. The prediction errors were found to be less then 7%, demonstrating the accuracy of the object oriented finite element (OOFE) modeling of the crack propagation process in the cobalt binder. It also demonstrates its capability in capturing the physics of the wear process. This is attributed to the fact that the OOF model incorporates the real microstructure of the tool material.

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.

Tool Wear Characteristics in High Speed Milling of Ti-6Al-4V Alloy with Nitrogen Gas Medium

2006 ◽  
Vol 315-316 ◽  
pp. 588-592 ◽  
Author(s):  
Wei Zhao ◽  
Ning He ◽  
Liang Li ◽  
Z.L. Man
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Oil Mist ◽  
Electron Microscopes ◽  
Scanning Electron Microscopes

High speed milling experiments using nitrogen-oil-mist as cutting medium were undertaken to investigate the characteristics of tool wear for Ti-6Al-4V Alloy, a kind of important and commonly used titanium alloy in the aerospace and automobile industries. Uncoated carbide tools have been applied in the experiments. The cutting speed was 300 m/min. The axial depth of cut and the radial depth of cut were kept constant at 5.0 mm and 1.0 mm, respectively. The feed per tooth was 0.1 mm/z. Optical and scanning electron microscopes have been utilized to determine the wear mechanisms of the cutting tools, and energy spectrum analysis has been carried out to measure the elements distribution at the worn areas. Meanwhile, comparisons were made to discuss the influence of different cutting media such as nitrogen-oil-mist and air-oil–mist upon the tool wear. The results of this investigation indicate that the tool life in nitrogen-oil-mist is significantly longer than that in air-oil-mist, and nitrogen-oil-mist is more suitable for high speed milling of Ti-6Al-4V alloy than air-oil-mist.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

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.

High Speed Machining: A Review from a Viewpoint of Chip Formation

2011 ◽  
Vol 188 ◽  
pp. 578-583 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Masahiro Anzai ◽  
Tsuneo Egawa ◽  
Norihiko Narutaki ◽  
Kazuhiro Shintani ◽  
...  
Keyword(s):  
Tool Wear ◽  
Life Span ◽  
High Speed ◽  
Cutting Speed ◽  
Strong Nonlinearity ◽  
High Speed Machining ◽  
Cast Irons ◽  
Sliding Test ◽  
Cutting Experiments ◽  
Cutting Speeds

This paper describes strong nonlinearity in log V-log L relationship, which is often found in machining of supperalloys, titanium alloys, hardened steels, cast irons, etc. The nonlinearity plays an important and favorable role in extension of life-span cutting distance at higher cutting speeds; that is, in a certain range of cutting speed, life-span cutting distance increases with cutting speed. Results of tool wear in a sliding test and cutting experiments, which showed the evidences of strong nonlinearity, were investigated and the mechanisms causing the nonlinearity were discussed.

Sign in / Sign up

Export Citation Format

Share Document