Machining of Difficult-to-Cut-Alloys Using Rotary Turning Tools

Olgun, Utku; Budak, Erhan

doi:10.1016/j.procir.2013.06.069

Cited by 38 publications

(15 citation statements)

References 14 publications

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“…Cutting temperature generated during machining is significantly influenced by cutting conditions [ 31 , 32 ] and cutting tool materials and geometry [ 33 , 34 ]. Various studies have been conducted in order to reduce the temperature during the machining of titanium alloys, and these have been based on optimizing cutting conditions or used methods such as vibration assisted machining [ 35 ] which showed a good result in reducing temperature of cutting, using a rotary tool [ 36 ], using lubrication to reduce friction between the tool and target material [ 37 ] or using emerging cooling systems [ 38 ].…”

Section: Introductionmentioning

confidence: 99%

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

et al. 2020

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This article presents the results of an experimental investigation into the machinability of Ti6Al4V alloy during hard turning, including both conventional and high-speed machining, using polycrystalline diamond (PCD) inserts. A central composite design of experiment procedure was followed to examine the effects of variable process parameters; feed rate, cutting speed and depth of cut (each at five levels) and their interaction effects on surface roughness and cutting temperature as process responses. The results revealed that cutting temperature increased with increasing cutting speed and decreasing feed rate in both conventional and high-speed machining. It was found that high-speed machining showed an average increase in cutting temperature of 65% compared with conventional machining. Nevertheless, high-speed machining showed better performance in terms of lower surface roughness despite using higher feed rates compared to conventional machining. High-speed machining of Ti6Al4V showed an improvement in surface roughness of 11% compared with conventional machining, with a 207% increase in metal removal rate (MRR) which offered the opportunity to increase productivity. Finally, an inverse relationship was verified between generated cutting temperature and surface roughness. This was attributed mainly to the high cutting temperature generated, softening, and decreasing strength of the material in the vicinity of the cutting zone which in turn enabled smoother machining and reduced surface roughness.

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Section: Introductionmentioning

confidence: 99%

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

et al. 2020

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“…The overwhelming majority of works [7][8][9][10][11][12][13][14][15][16][17][18][19][20][21] dealing with rotary cutting consider the process of rotary turning or shaping as applied to a smooth cutting element in the form of a truncated cone, the cutting edge of which is a circle. This shape of the cutting element is predetermined by the manufacturability and is optimal for processing cylindrical (turning) and flat (shaping) workpiece surfaces.…”

Section: Rotary Milling As a Methods Of Obtaining Discontinuous Chipsmentioning

confidence: 99%

Dynamics of Rotary Milling According to Group Scheme of Obtaining Discontinuous Chips

Smetanin

Shalamov

2018

Proceedings of the 4th International Conference on Industrial Engineering

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The forces, oscillations, or vibrations arising in the process of cutting must be taken into account, when optimizing any process operation or process. One of the high-performance machining processes is rotary cutting. However, the presence of an additional rotation of cutting elements decreases the rigidity of rotary tools, increases the variability of the operating forces, which require studying vibration dynamic phenomena at rotary processing. Rotary milling, being an intermittent cutting process, increases the possibility of obtaining discontinuous chips. The cutting tool operation according to the group cutting scheme is also used for efficient chip breaking. The measurements were carried out using a dynamometer and a spectrum analyzer. The obtained results reflect the dynamics of the rotary milling process and qualitatively coincide with the dynamic phenomena at conventional face milling and rotary turning. However, at the same time, we revealed characteristic features predetermined by the operation of the toothed cutting element according to the group cutting scheme.

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“…The experimental results showed that the DRT can significantly increase tool life. Olgun et al [17] compared experimentally self-propelled rotary turning (SPRT) tools and actively driven rotary turning (ADRT) tools in terms of the cutting performance, and found that SPRT process yielded better tool life and machined part quality. Kishawy et al [18][19][20] presented the models for predicting cutting forces, flank wear and chip flow to evaluate the cutting performance of self-propelled rotary tools in the machining process, and verified the correctness of predicted values by the experiments on machining the titanium alloy.…”

Section: Introductionmentioning

confidence: 99%

Research on cutting performance in high-speed milling of TC11 titanium alloy using self-propelled rotary milling cutters

Yujiang

Chen

2021

Int J Adv Manuf Technol

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Titanium alloy materials, with excellent chemical and physical properties, are widely applied to the manufacture of key components in the aerospace industry. Nevertheless, its hard-to-machine characteristic causes various problems in the machining process, such as severe tool wear, difficulty to ensure good surface quality, etc. To achieve high efficiency and quality of machining titanium alloy materials, this paper conducted an experimental research on the high-speed milling of TC11 titanium alloy with self-propelled rotary milling cutters. In the work, the wear mechanism of self-propelled rotary milling cutters was explored, the influence of milling velocity was analyzed on the cutting process, and the variation laws were obtained of milling forces, chip morphology and machined surface quality with the milling length. The results showed that in the early and middle stages of milling, the insert coating peeled off evenly under the joint action of abrasive and adhesive wear mechanisms. As the milling length increased, the dense notches occurred on the cutting edge of the cutter, the wear mechanism converted gradually into fatigue wear, and furthermore coating started peeling off the cutting edge with the occurrence of thermal fatigue cracks on the insert. As the milling length was further extended, the milling forces tended to intensify, the chip deformation worsened, and the obvious cracks occurred at the bottom of chips. Moreover, the rise in milling velocity reduced the tool wear resistance, increased obviously the milling forces and the surface roughness.

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Machining of Difficult-to-Cut-Alloys Using Rotary Turning Tools

Cited by 38 publications

References 14 publications

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

Dynamics of Rotary Milling According to Group Scheme of Obtaining Discontinuous Chips

Research on cutting performance in high-speed milling of TC11 titanium alloy using self-propelled rotary milling cutters

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