An Experimental and Numerical Approach to Study the Performance of Modified Perforated Cutting Tools on Machining of Ti–6Al–4V Alloy

Rao, Charitha M.; Rao, Shrikantha S.; Herbert, Mervin A.

doi:10.1007/s13369-019-04268-w

Cited by 10 publications

(4 citation statements)

References 54 publications

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“…To enhance the effectiveness of the method, different kinds of lubricants have been used in industries [1]. Liquid nitrogen (LN 2 ) is one such coolant that has been efficiently used as a lubricant [2]. Some of the notable benefits of LN 2 are: it is environment-friendly, and also it does not have much impact on the operator [3,4].…”

Section: Introductionmentioning

confidence: 99%

Influence of slide burnishing process on the surface characteristics of precipitation hardenable steel

Sachin¹,

Rao

Naik

et al. 2021

SN Appl. Sci.

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The surface integrity of the material is the predominant necessity of a component to perform efficiently in varying working conditions. To improve the surface integrity of the workpiece secondary finishing processes are being performed. This work attempts to propose a realistic cryogenic slide burnishing condition for improvement of the surface integrity. The slide burnishing was performed by a novel slide burnishing tool on 17–4 precipitation hardenable stainless steel. The experiment was designed based on a central composite design. Initially, the effect of control parameters on the output response was examined by experimental analysis based on the design of experiment. Analysis of variance was used to analyze the influence of the variables on the performance indices. The regression technique was used to develop an empirical model. Optimization of process parameters for finding minimum surface roughness and maximum surface hardness was achieved by a multi-objective genetic algorithm. The optimized solutions were validated by performing confirmation experiments.

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Section: Introductionmentioning

confidence: 99%

Influence of slide burnishing process on the surface characteristics of precipitation hardenable steel

Sachin¹,

Rao

Naik

et al. 2021

SN Appl. Sci.

Self Cite

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“…The micro-defects on the workpiece material played a very important role in the formation of the lamellar structure. Due to the instability of the thermo-plastic flow micro-defects could appear in the shear surface, resulting in layer by layer slipping [29]. As the Fig.…”

Section: Chip Morphologymentioning

confidence: 99%

Effect of Volcano-like Textured Coated Tools on Machining of Ti6Al4V: An Experimental and Simulative Investigation

Zhou

Yang

2021

Preprint

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In this work, the main aim is to reduce the adhesion and wear that happened during machining of the Ti6Al4V alloy by employing volcano-like texture on the rake face of coated tool. A combination of experimental and simulative investigation was adopted. DEFORM-3D software with updated Lagrangian formulation was used for numerical simulation, and the thermo-mechanical analysis was performed using Johnson-Cook material model to predict the cutting temperature, cutting forces, chip morphology and tool wear. In cutting experiments, volcano-like textures with different area densities (10%, 20%, 30%) were fabricated by fiber laser on the rake face of cemented carbide tools close to the main cutting edge. Then, these textured tools were deposited with CrAlN coating through cathodic vacuum arc ion plating technique. Experiments in cutting Ti6Al4V alloy were carried out with the textured coated tools and non-textured coated tool under dry and wet cutting conditions. Then, the chip morphology, chip size and tool wear were investigated. The results showed that textured coated tools were superior to conventional tool. Especially in wet cutting, compared with those of non-textured coated tool, the adhesion area and the chip curling radius of the coated tool with texture area density of 20% (VCT2) were reduced by 31.2% and 49.7%, respectively. Therefore, VCT2 tool showed a better cutting performance. Finally, the mechanisms of textured coated tools under dry and wet cutting conditions were proposed.

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“…The results showed that semi-elliptical tools can effectively reduce the wear depth and surface temperature of the tool, and for different textures, the parameter changes were more stable. Scholars [22][23][24] pointed out that the cutting force and cutting temperature of the textured tools are significantly reduced compared with those of non-textured tools. Textured tools can not only reduce the tool-chip contact length, but also decrease the roughness of the machined surface, improve the machining quality, and provide technical support for the cutting process of factories.…”

Section: Introductionmentioning

confidence: 99%

Effect of volcano-like textured tools on machining of Ti-6Al-4V alloy: a numerical and experimental analysis

Liu¹,

Fu²,

Zhou³

et al. 2022

Surf. Topogr.: Metrol. Prop.

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Higher temperature and lower thermal conductivity between the tool-chip contact face easily result in adhesion and wear on the tool surface which negatively affects the tool life and the machining quality of the workpiece in the machining Ti-6Al-4V alloy process. To address these problems, the investigation, combining the simulation and experiment, introduced the volcano-like textures of different diameters with excellent anti-adhesion performance on the tool rake face. DEFORM-3D software with updated Lagrangian formulation was used for numerical simulation, and the thermo-mechanical analysis was performed using the Johnson-Cook material model to predict the cutting forces, cutting temperature and tool wear. In cutting experiments, volcano-like textures (VT) with different diameters were fabricated by fiber laser on the rake face of cemented carbide tools close to the main cutting edge. Experiments in cutting Ti-6Al-4V alloy were carried out with the textured tools and non-textured tool under rough machining, semi-finishing and finishing conditions. Then, cutting force, cutting temperature and tool wear were investigated. The results showed that textured tools generally perform better than non-textured tools. The cutting force of VT1 was reduced by 31.2% and 50%, respectively, compared with the non-textured tool under Semi-finishing and finishing conditions. With the refinement of machining, the cutting performance of the textured tools is improved, and the service life of the tool is extended. Therefore, the investigation can provide a basis for the surface texture design and optimization of the carbide tool.

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An Experimental and Numerical Approach to Study the Performance of Modified Perforated Cutting Tools on Machining of Ti–6Al–4V Alloy

Cited by 10 publications

References 54 publications

Influence of slide burnishing process on the surface characteristics of precipitation hardenable steel

Influence of slide burnishing process on the surface characteristics of precipitation hardenable steel

Effect of Volcano-like Textured Coated Tools on Machining of Ti6Al4V: An Experimental and Simulative Investigation

Effect of volcano-like textured tools on machining of Ti-6Al-4V alloy: a numerical and experimental analysis

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