Experimentally validated calculation of the cutting edge temperature during dry milling of Ti6Al4V

Nemetz, Andreas W.; Daves, Werner; Klünsner, Thomas; Praetzas, Christopher; Liu, Wenqi; Teppernegg, Tamara; Czettl, Christoph; Haas, Franz; Bölling, Christian; Schäfer, Jonathan

doi:10.1016/j.jmatprotec.2019.116544

Cited by 30 publications

(7 citation statements)

References 29 publications

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“…As aforementioned, the generated heat in the shear zone could be transported away with chip flow. In this respect, CVD Al 2 O 3 is considered a good thermal barrier for preventing the plastic deformation of substrates [1,7,8]. Compared with α-Al 2 O 3 , κ-Al 2 O 3 shows a much smaller thermal conductivity.…”

Section: Metal Cutting Testmentioning

confidence: 99%

“…In the case of continuous cylindrical turning, the workpiece rotates around its center axis, while a sharp-edged tool is set to a certain depth of cut for performing a facing operation towards the workpiece rotational center [6]. In contact zones, high temperatures are reached, where thick coatings (≈5-20 µm) with low thermal conductivities are accepted as favorable since they provide a thermal barrier to the substrate, and the generated heat is deflected into the chip, preventing the plastic deformation of the underlying substrate [1,7].…”

Section: Introductionmentioning

confidence: 99%

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Characteristics and Cutting Performance of CVD Al2O3 Multilayer Coatings Deposited on Tungsten Carbide Cutting Inserts in Turning of 24CrMoV5-1 Steel

Zhu,

Achache,

Motta

et al. 2023

Coatings

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In this work, TiN/Ti(C,N)/Al2O3 multilayer coatings were deposited using an industrial-scale thermal CVD system. Two polymorphs of Al2O3, the stable α- and the metastable κ-Al2O3, were obtained by the deposition of specific bonding layers at the Al2O3/Ti(C,N) interface. The comparable hardness and elastic moduli of α- and κ-Al2O3 multilayer coatings were measured. The tribological behavior of Al2O3 multilayer coatings was studied at room temperature using 24CrMoV5-1 balls; friction coefficients were comparable for both α- and κ-Al2O3 multilayer coatings. As a result of the relatively high hardness of coatings and the generation of abrasive wear particles, larger wear tracks were observed on balls. In Rockwell C tests, good adhesion at Al2O3/Ti(C,N)-based layer’s interface was reported in κ-Al2O3 multilayer coatings, which could be attributed to the deposition of κ-bonding layers consisting of needle-shaped grains. The cutting performances in the turning-roughing of 24CrMoV5-1 steel under different parameters—cutting speed, feed, and depth of cut—were investigated. Herein, κ-Al2O3 multilayer coatings showed the longest tool life, double of that of a commercial CVD Al2O3 multilayer coating. The results obtained could enrich the existing database for the development of prediction models of tool wear and machined surface quality and help improve tool performance for the machining of 24CrMoV5-1 steel.

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Section: Metal Cutting Testmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Characteristics and Cutting Performance of CVD Al2O3 Multilayer Coatings Deposited on Tungsten Carbide Cutting Inserts in Turning of 24CrMoV5-1 Steel

Zhu,

Achache,

Motta

et al. 2023

Coatings

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“…As the tool cuts the workpiece, the cutting edge structure changes, leading to changes in the contact area between the tool and workpiece, resulting in a fluctuation in cutting force. Changes in the cutting edge can initiate changes in the squeezing and friction between the cutting edge and the workpiece, which in turn affect the temperature change during cutting (Nemetz et al, 2020). Various physical parameters, such as cutting force and cutting temperature, impact the tool's cutting stability, tool wear, and the quality of the machined surface to varying degrees during metal cutting.…”

Section: Open Access Edited Bymentioning

confidence: 99%

State-of-the-art and perspectives of cutting edge preparation and its effect on the cutting performance of titanium alloy

Pan

Yuan

2023

Front. Mater.

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Titanium alloys are commonly used in industrial applications due to their exceptional mechanical and chemical properties. However, their low thermal conductivity and high chemical reactivity pose significant challenges in machining, leading to increased cutting forces, rapid tool wear, and poor surface quality. To overcome these issues, advanced cutting edge preparation techniques have been developed to enhance the machining performance of titanium alloys. This paper provides an overview of state-of-the-art cutting edge preparation techniques for titanium alloy machining and examines their effects on machining performance. It first presents a characterization method for cutting edge geometry and explores how it affects machining performance, demonstrating that strategic cutting edge preparation can significantly enhance performance by reducing cutting forces and improving surface finish. The paper also emphasizes the underlying mechanisms of cutting edge preparation and its impact on machining performance and subsequent cutting edge erosion. Finally, it concludes by discussing future research directions in this field, highlighting the need to develop new cutting edge preparation techniques and optimize existing ones. Overall, this paper serves as a valuable resource for researchers and engineers seeking to improve the cutting performance of titanium alloys in various applications.

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“…It is well known that the machining temperature is influenced by the cutting parameters, the cutting tool technology used and the material properties of the workpiece. Moreover, numerical simulations have been used to study the temperature of the tool-chip interface during the Ti6Al4V milling process [19,[22][23][24], although these do not describe the effects of the cutting parameters on the cutting temperature. Li et al [13] studied the effects of the cutting speed on the cutting edge and workpiece temperature of Ti6Al4V during the milling process, and found that the heat generation increases with the cutting speed.…”

Section: Influence Of the Machining Process Of Cfrp And Titanium On Cutting Temperaturementioning

confidence: 99%

Temperature Study during the Edge Trimming of Carbon Fiber-Reinforced Plastic [0]8/Ti6Al4V Stack Material

et al. 2021

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Carbon Fiber-Reinforced Plastic (CFRP) and Titanium alloy (Ti6Al4V) stacks are used extensively in the modern aerospace industry thanks to their outstanding mechanical properties and resistance to thermal load applications. Machining the CFRP/Ti6Al4V stack is a challenge and is complicated by the differences in each constituent materials’ machinability. The difficulty arises from the matrix degradation of the CFRP material caused by the heat generated during the machining process, which is a consequence of the low thermal conductivity of Ti6Al4V material. In most cases, CFRP and Ti6Al4V materials are stacked and secured together using rivets or bolts. This results in extra weight, while the drilling process required for such an assembly may damage the CFRP material. To overcome these issues, some applications employ an assembly that is free of bolts or rivets, and which uses adhesives or an adapted curing process to bond both materials together. The present research analyzes a thermal distribution and its effect on quality during the edge trimming process of a CFRP/Ti6Al4V stack assembly. Different types of tools and cutting parameters are compared using thermocouples embedded within the material and others on the tool cutting edge. In contrast to previous studies, the feed rate was the most significant factor affecting the cutting temperature and quality of the workpiece, while the cutting speed had no significant impact. The temperature in the workpiece increases as the feed per tooth decreases.

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Experimentally validated calculation of the cutting edge temperature during dry milling of Ti6Al4V

Cited by 30 publications

References 29 publications

Characteristics and Cutting Performance of CVD Al2O3 Multilayer Coatings Deposited on Tungsten Carbide Cutting Inserts in Turning of 24CrMoV5-1 Steel

Characteristics and Cutting Performance of CVD Al2O3 Multilayer Coatings Deposited on Tungsten Carbide Cutting Inserts in Turning of 24CrMoV5-1 Steel

State-of-the-art and perspectives of cutting edge preparation and its effect on the cutting performance of titanium alloy

Temperature Study during the Edge Trimming of Carbon Fiber-Reinforced Plastic [0]8/Ti6Al4V Stack Material

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