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

Abstract

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.

Subroutine Embedding and Finite Element Simulation of the Improved Constitutive Equation for Ti6Al4V during High-Speed Machining

“…It is more reasonable that the constitutive model has different expressions to describe the stress changes of all strain intervals. The improved J-C constitutive model is shown in Equation (2).…”

“…Titanium alloy is a widespread application in all fields of life, such as marine, automotive, aviation, sports, medicine, and so on because of its good plasticity, high strength, temperature resistance, and corrosion resistance [1][2][3]. It is true that the titanium alloys have a relatively low level of processing efficiency and quality, and the recommended cutting speed is 30~50 m/min with cemented carbide tools in production [4,5].…”

Evaluation of crude watermelon oil as lubricant in cylindrical turning of AISI 1525 steel employing Taguchi and grey relational analyses techniques

“…The distortion of the metal in the shear region in the path of the cutting edge, the physical separation of the metal at the point of separation, and the rubbing action of the chip, as it contacts over the tool's surface as it gets pushed out of the way, are the three processes that generate heat [ [4] , [5] , [6] , [7] ]. The two main types of tool wear caused by heat generation are crater wear and flank wear, which limit the life of the tool and lead to dimensional inaccuracies, surface deterioration, and extreme corrosion situations on the workpiece [ 8 ]. The heat at the cutting region can be decreased by selecting the proper cutting settings, selecting the appropriate cutting instruments, and applying cutting fluids [ 9 , 10 ].…”

Analysis of Dual-Driven Feed System Vibration Characteristics Based on Computer Numerical Control Machine Tools: A Systematic Review

“…Since the world is transitioning from the third to the fourth industrial revolution, manufacturing organizations need more open and interoperable systems to be confident with increasingly frequent and unpredictable market changes [1,2]. The automobile, aerospace, shipbuilding, mold, and energy industries have increasingly adopted high-speed machining technology as the modern manufacturing sector has emerged [3][4][5][6]. Vibration in machining is an essential factor affecting its accuracy for high-speed CNCMT.…”