Analytical modeling of tool failure boundary map in milling titanium alloy

Du, Yanjie; Yue, Caixu; Li, Xiao-chen; Liu, Xianli; Liang, Steven Y.

doi:10.1177/09544054211043981

Cited by 4 publications

(3 citation statements)

References 23 publications

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“…At present, the tool remaining useful life prediction is mainly based on failure information, performance degradation information, or wear amount. Wiener process, Gamma process, or competitive failure model are applied and combined with the failure threshold [2][3][4][5][6][7][8][9][10]. However, collecting a large amount of life data for mechanical products, such as machine tools, in a short period of time is difficult compared with electronic products.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Tool Remaining Useful Life Based on NHPP-WPHM

et al. 2023

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A tool remaining useful life prediction method based on a non-homogeneous Poisson process and Weibull proportional hazard model (WPHM) is proposed, taking into account the grinding repair of machine tools during operation. The intrinsic failure rate model is built according to the tool failure data. The WPHM is established by collecting vibration information during operation and introducing covariates to describe the failure rate of the tool operation. In combination with the tool grinding repair, the NHPP-WPHM under different repair times is established to describe the tool comprehensive failure rate. The failure threshold of the tool life is determined by the maximum availability, and the remaining tool life is predicted. Take the cylindrical turning tool of the CNC lathe as an example, the root mean square error, mean absolute error, mean absolute percentage error, and determination coefficient (R2) are used as indicators. The proposed method is compared with the actual remaining useful life and the remaining useful life prediction model based on the WPHM to verify the effectiveness of the model.

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Section: Introductionmentioning

confidence: 99%

Prediction of Tool Remaining Useful Life Based on NHPP-WPHM

et al. 2023

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“…Titanium alloy is an ideal manufacturing material that is used in aircraft and engines because of its high specific strength, good mechanical properties, and good corrosion resistance. 1,2 However, due to its poor machinability, its application is limited. [3][4][5] In order to improve the machinability of titanium alloy, many cutting methods and machining technologies have been proposed.…”

Section: Introductionmentioning

confidence: 99%

Study of electrical pulse heat assisted cutting of titanium alloy TC21 based on the finite element method

Qian

Zhang

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Titanium alloys are widely used in various fields because of their high strength, excellent corrosion resistance, and high heat resistance. As a new advanced titanium alloy for aviation, TC21 titanium alloy has high strength and poor machinability. It is of great significance to study the cutting mechanism of this alloy and the methods to improve the machinability of aircraft. In this paper, aiming at the difficult machinability of titanium alloy TC21, EPH online heating assisted cutting method is put forward for the first time. During the cutting experiment, the TC21 alloy sample was heated to a variety of temperatures through the electric pulse thermal heat technique. Chip shape and cutting force under different heating temperatures were obtained by cutting experiments. In order to study the influence of the heat-assisted cutting process on the machining of TC21 alloy, the orthogonal finite element model was proposed to simulate the heat-assisted cutting process of TC21 alloy. Through this simulation, chip formation, cutting force, and cutting temperature variation were all obtained. The chip formed by the simulation was in accordance with the actual chip. The results demonstrate that the influence of heat-assisted machining on chip morphology of titanium alloy is relatively small, but it has a significant influence on cutting force and surface roughness. The results show that when the sample is heated to 600°C, the surface quality is the best and cutting force can be reduced by more than 40%.

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“…6 Moreover, the poor thermal conductivity of titanium alloy retards the dissipation of cutting-induced heat, thereby induces a very high temperature at the tool-workpiece interface even at lower cutting speed. 7 The high temperature concentrated to the cutting edge adversely reduces the tool life 8 and severely destroys the finished surface quality. 9,10 Especially, the instability of the segmented chip formation process in the machining of titanium is responsible for fluctuations of cutting forces.…”

Section: Introductionmentioning

confidence: 99%

Machinability improvement of titanium alloys in ultra-precision machining with micro-structured surface

Sujuan,

Liangbao,

Chao

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Titanium alloys get wider applications in different areas due to its excellent mechanical properties. However, poor thermal conductivity and low elastic module of titanium alloy induce high tool wear and make it being one of hard-to-machine materials; especially the segmented chip formation accelerates the diamond tool wear in ultra-precision machining (UPM) of precision parts. This study applies micro-structured surface to improve machinability of titanium alloys in UPM by reducing the chip segmentation induced cutting forces fluctuations. Finite element (FE) model is built to study chip formation mechanism and characterize geometries of segmented chips in orthogonal diamond cutting of Ti6Al4V alloy with the aims at the design of micro-structures array. Turning experiments are conducted to compare cutting force, surface roughness, and tool wear for diamond turning of Ti6Al4V alloy on smooth surface and micro-structured surface. The results show that the FE simulated saw chips agree well with the measured ones. Moreover, the micro-structured surface helps to decrease cutting force, reduce diamond tool wear, and improve surface quality for UPM of titanium alloy. Especially, the new method fabricates micro-grooves array on the machined surface in half-finishing process of UPM without the need of any material pre-processing and extra manufacturing equipment, which can also provide the guidance for efficient and sustainable UPM of titanium alloys parts with high surface quality.

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Analytical modeling of tool failure boundary map in milling titanium alloy

Cited by 4 publications

References 23 publications

Prediction of Tool Remaining Useful Life Based on NHPP-WPHM

Prediction of Tool Remaining Useful Life Based on NHPP-WPHM

Study of electrical pulse heat assisted cutting of titanium alloy TC21 based on the finite element method

Machinability improvement of titanium alloys in ultra-precision machining with micro-structured surface

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