Proposal of a combined experimental-simulation methodology for the evaluation of machining temperature in turning processes

García-Martínez, Enrique; Martínez, A; Tendero, María Carmen Manjabacas; Miguel, V.

doi:10.1016/j.measurement.2021.110632

Cited by 10 publications

(9 citation statements)

References 28 publications

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“…The three main components of the cutting force and their evolution were registered by using a three-axis dynamometer, built by the research team, with a capability of measuring forces up to 5000 N and a resolution lower than 1 N. The dynamometer is composed for four strain-gauge load cells that were calibrated under static conditions and validated in previous studies [21]. The temperature for cutting operations with uncoated WC inserts was registered by using a natural workpiece-thermocouple technique formed by the contact pair workpiece-tool, that is, Ti48Al2Cr2Nb-WC/Co, verified for this kind of application in previous research [22]. According to the calibration data, the uncertainty of the instrument could be fixed in the range 7-8% within the range of temperatures involved in this research.…”

Section: Experimental Methodologymentioning

confidence: 76%

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Optimization of the Dry Turning Process of Ti48Al2Cr2Nb Aluminide Based on the Cutting Tool Configuration

et al. 2022

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Titanium aluminides are one of the most promising materials in aeronautical and automotive applications. However, their low machinability makes the processing of these alloys quite difficult under sustainability conditions, specially without lubrication. The current study focuses on the turning process of the Ti48Al2Cr2Nb gamma titanium aluminide under dry conditions. As far as we are aware, dry cutting is the most sustainable feature, although it has not been traditionally applied on titanium aluminides due to the accelerated tool wear that the material promotes. The main novelty of this work consists of providing a simple solution for reducing the tool wear based on the inclination of the cutting insert, what is evaluated in terms of tool wear and tool life, cutting forces, cutting temperature, surface integrity of the machined part, as well as its microhardness and microstructural effects. The results shown here clearly point out a better performance of the machining process. This fact could be understood if we take into consideration that an increment of the clearance angle from 6.3° to 11.6° and 15° increases the tool life by five and six times, respectively, using efficient cutting speeds, whose values have increased by 50% with respect to the original cutting conditions. This improvement is explained according to the reduction in the cutting temperature and friction forces in the flank face of the tool. In addition, the use of uncoated carbide inserts may lead to a better behaviour than the coated ones, considering the results obtained for a PVD TiAlN + AlCr2O3 coated insert herein researched.

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Section: Experimental Methodologymentioning

confidence: 76%

“…This value really corresponds to the temperature in the chip-tool-workpiece area. Nevertheless, these recorded values are near the upper limit for the natural thermocouple to be operative [22]. Thus, it is advisable to analyse the evolution of the temperature with the tool wear without considering the feed rate.…”

Section: Temperature Analysismentioning

confidence: 95%

Optimization of the Dry Turning Process of Ti48Al2Cr2Nb Aluminide Based on the Cutting Tool Configuration

et al. 2022

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“…This technique requires a specific calibration methodology. More details about the use of this procedure for Ti48Al2Cr2Nb-WC/Co pair can be found in specific research [33]. identified.…”

Section: Methodsmentioning

confidence: 99%

“…This technique requires a specific calibration methodology. More details about the use of this procedure for Ti48Al2Cr2Nb-WC/Co pair can be found in specific research [33]. The cutting speed's influence on surface integrity, subsurface hardening, and microstructural alterations was analyzed under MQL conditions.…”

Section: Methodsmentioning

confidence: 99%

“…Although the MQL technique is not focused directly on temperature reduction, it was found that the reduction in friction allows the cutting temperature to be reduced by about 100 • C. Due to the difficulty of measuring the cutting temperature because of the high values existing, which is in the upper limit of the thermocouple working range, it was decided to evaluate and compare the temperature when the cutting is interrupted. Figure 4 shows the tool-workpiece temperature due to the friction and ploughing phenomena on the flank face of the tool once the feed rate is removed, maintaining the tool in contact while the cylinder is rotating, according to the methodology established in previous research [33]. The heat is only generated in the third deformation zone (flank wear band), so the lower values found for the MQL condition imply a reduction in the friction phenomenon in that zone thanks to the effective lubrication.…”

Section: Temperaturementioning

confidence: 99%

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Effect of Minimum Quantity of Lubricant on Carbide Tools and Surface Integrity in the Machining of Titanium Aluminides

García-Martínez,

Miguel,

Martínez-Martínez

2024

Metals

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Titanium aluminides are being explored as potential materials for the aeronautical sector. However, their application is limited by the high costs of processing and their difficulties in machining. This research evaluates the effectiveness of the minimum quantity lubrication technique (MQL) on the turning process of Ti48Al2Cr2Nb aluminide in terms of tool wear, tool life, cutting forces, surface integrity, and temperature. It was found that MQL conditions can improve the process efficiency, reducing the thermally induced wear mechanisms and enlarging the tool life compared to dry machining. Furthermore, it allows the cutting speed to be incremented, leading to lower processing times. However, MQL seems to not be effective in the reduction of the strain-hardening effect near the machined surface and, although the number of microcracks is reduced, defect-free surfaces cannot be obtained. Moreover, similar microstructural alterations as for dry cutting were detected. The best cutting conditions in terms of surface quality were assessed using the central composite face (CCF) design and surface response methodology. Optimization of the surface roughness under industrially viable cutting conditions was achieved with an average surface roughness value, Ra, of 0.29 µm (feed rate of 0.05 mm/rev, a cutting speed of 54.6 m/min and a depth of cut of 0.125 mm).

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A new model to predict the tool life in turning of titanium aluminides

García-Martínez

Miguel

Martínez

et al. 2023

Int J Adv Manuf Technol

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Several tool wear models for machining operations have been reported in the literature. However, most of them are capable of modeling only a part of the wear curve, designed for quasi-linear curves or need to be fitted by means of differential equations. In this research, a new analytical easy-to-use wear model is proposed, taking into consideration the geometry of the cutting insert and the influence of the cutting speed and the tool-workpiece contact stress. In addition, the effect of the critical machining time, relative to the tool degradation, has also been introduced. The wear model describes completely the wear curve, from the initial rapid wear stage to the thermal-activated wear rate acceleration. The constants and parameters of the equation are determined by cutting experiments from the cutting forces and flank wear registers under a variety of technological parameters. This model has been validated for turning process on Ti48Al2Cr2Nb aluminide with uncoated carbide tool under different cutting conditions, varying the cutting speed and the geometrical position of the tool. It has been demonstrated its suitability to predict tool life, according to a defined wear criterion.

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Proposal of a combined experimental-simulation methodology for the evaluation of machining temperature in turning processes

Cited by 10 publications

References 28 publications

Optimization of the Dry Turning Process of Ti48Al2Cr2Nb Aluminide Based on the Cutting Tool Configuration

Optimization of the Dry Turning Process of Ti48Al2Cr2Nb Aluminide Based on the Cutting Tool Configuration

Effect of Minimum Quantity of Lubricant on Carbide Tools and Surface Integrity in the Machining of Titanium Aluminides

A new model to predict the tool life in turning of titanium aluminides

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