On the Volumetric Assessment of Tool Wear in Machining Inserts With Complex Geometries—Part II: Experimental Investigation and Validation on Ti-6Al-4V

Abstract

In part 1, traditional methods of tool wear characterization were qualitatively assessed, and consequently a volumetric approach of wear quantification was developed, standardized, and evaluated using a gauge R&R study. The objective of this paper is to experimentally investigate and validate this assessment methodology using the wear results from a series of controlled machining experiments on grade-5 titanium alloy. The traditionally difficult-to-machine alloy, TÍ-6AI-4V, was specifically chosen as the work material in order to highlight how the use of this assessment methodology is necessitated especiatty because of(i) the pronounced comptexities in the geometric profites of typicat cutting toots emptoyed for machining its nonconformity in behavior with standard toot wear modets, such as the Taytor's toot tife modet and its extensions. This assessment methodology is then vatidated through the simuttaneous anatysis and comparison of traditional flank wear and associated photomicrographs with volumetric wear and its evolution. Furthermore, the concept of the M-ratio and its derivatives are developed to quantify the efficiency of the cutting tool during each pass at a constant material removal rate (MRR).

Evaluating the effectiveness of the novel surface textured tools in enhancing the machinability of titanium alloy (Ti6Al4V)

“…These typically limit the cutting speeds and feeds and eventually the productivity. (Kuttolamadom et al 2012) Fig . 13 shows the difference in the wear characteristics of tools while machining steel and titanium alloys.…”

Correlation of the Volumetric Tool Wear Rate of Carbide Milling Inserts With the Material Removal Rate of Ti–6Al–4V

“…Volumetrically quantifying wear has the advantage of not being tool/workpiece/process combination restricted, and can be used for almost any complex tool profile or wear behavior [1,9,10], 2.2 VTW. The inconsistent wear quantification scenario depicted in Fig.…”

“…1 is just one among many that are commonly encountered; hence, strictly speaking, none of the traditional tool wear studies can be compared absolutely. Rightly so, machining tool wear has historically been described as "difficult to define without ambiguity" [11], Prior conducted volumetric wear related efforts by contact mechanics [12][13][14][15] and optical assessment [16][17][18][19][20][21][22][23][24][25] have been extended [1,5,9,10,26,27] in which a VTW methodology was developed, evaluated by a gauge R&R, and validated. Further, a comparative analysis [1,9] has substantiated the necessity and advantages of this methodology over prior efforts.…”

Analysis of Results of Non-Contact Coordinate Measurement of a Cutting Tool Applied for Mould Machining

“…Methods applied for measurements of tool wear often use image processing [10][11]. However, they are usually applied for coarse monitoring of the condition of a tool and they do not allow for obtaining more detailed information about the geometry of a tool as well as its worn parts, as presented, among others, in works [12][13][14][15]. Nowadays, coordinate measuring machines (CMMs) are very often used in many manufacturing industries and research laboratories due to e.g., the accuracy of the inspection process of components characterized by different shapes and dimensions [16][17][18][19].…”