The effect of titanium alloy chemistry on machining induced tool crater wear characteristics

Hatt, Oliver; Lomas, Zak; Thomas, Matthew; Jackson, M.

doi:10.1016/j.wear.2018.05.020

Cited by 33 publications

(18 citation statements)

References 24 publications

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“…There is an increase in the demand for titanium alloys especially in the aerospace industries [30,31]. In aerospace industries, titanium alloys are not only used for making fan blades, landing gear and other engine parts, but also for making fasteners for new lightweight carbon fiber fuselage and wings [32]. An example is the transition to carbon fiber fuselage and wings in Airbus A380-800, a major change from the materials selected for Airbus A340 [32,33].…”

Section: Machining Techniquesmentioning

confidence: 99%

An overview of conventional and non-conventional techniques for machining of titanium alloys

et al. 2020

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Machining is one of the major contributors to the high cost of titanium-based components. This is as a result of severe tool wear and high volume of waste generated from the workpiece. Research efforts seeking to reduce the cost of titanium alloys have explored the possibility of either eliminating machining as a processing step or optimising parameters for machining titanium alloys. Since the former is still at the infant stage, this article provides a review on the common machining techniques that were used for processing titanium-based components. These techniques are classified into two major categories based on the type of contact between the titanium workpiece and the tool. The two categories were dubbed conventional and non-conventional machining techniques. Most of the parameters that are associated with these techniques and their corresponding machinability indicators were presented. The common machinability indicators that are covered in this review include surface roughness, cutting forces, tool wear rate, chip formation and material removal rate. However, surface roughness, tool wear rate and metal removal rate were emphasised. The critical or optimum combination of parameters for achieving improved machinability was also highlighted. Some recommendations on future research directions are made.

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Section: Machining Techniquesmentioning

confidence: 99%

An overview of conventional and non-conventional techniques for machining of titanium alloys

et al. 2020

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“…Its intensity is enhanced when f is increased. High f and v c give rise to fast temperature increment that results in diffusion wear and crater formation [17,23]. Therefore, this wear mechanism is increased with v c and f.…”

Section: Dynamic Cutting Forces Amplitude Analysismentioning

confidence: 99%

“…On one hand, the chip sliding along the rake face gives rise to material adhesion on the tool. The alloy's low thermal conductivity quickly increases the temperature on the cutting area, resulting in fast chemical reactions that are responsible for the crater wear (diffusion from the work part (Ti, Al and V) to the cutting tool (W, Co and C)) [21][22][23]. On the other hand, flank wear is occasioned by the erosion of small fragments from the tool, due to material adhesion and its subsequent fracture that finally leads to a coating chipping.…”

Section: Introductionmentioning

confidence: 99%

Online Tool Wear Monitoring by the Analysis of Cutting Forces in Transient State for Dry Machining of Ti6Al4V Alloy

Hernández

Vilches

Gamboa

et al. 2019

Metals

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In this work, the analysis of the cutting speed and feed rate influence on tool wear and cutting forces in Ti6Al4V alloy dry machining is presented. The study has been focused on the machining in a transient state. The tool wear mechanisms, tool wear intensity and cutting forces evolution have been analyzed as a function of the cutting parameters. Experimental results show that the main cutting force amplitude exhibits a general trend to increase with both cutting parameters. Crater wear was more evident at high cutting speeds, whereas flank wear was present on the whole interval of the cutting parameters analyzed. Furthermore, the cutting speed shows a slightly higher influence on crater wear and the feed rate shows a higher influence on flank wear. Finally, several experimental parametric models have been obtained. These models allow predicting the evolution of crater and flank tool wear, as well as the cutting forces, as a function of the cutting parameters. Additionally, a model that allows monitoring the tool wear on the machining transient state as a function of the main cutting force amplitude has been developed.

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“…In general, a ball end milling cutter is utilized to produce the surface finish of titanium alloy. In that case, the forming of the helix angle and the rake angle of the end tooth is limited by the tool manufacturing method and fails to achieve the same design parameters as its cylindrical tooth [2][3][4][5][6][7][8]. The machining quality and application of titanium alloy parts are severely restricted by the physical characteristics of titanium alloy and the shortcomings of the existing tool.…”

Section: Introductionmentioning

confidence: 99%

An Experimental Study on Milling Titanium Alloy with a Revolving Cycloid Milling Cutter

et al. 2020

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In this paper, a revolving cycloid milling cutter was designed with a larger effective cutting helix angle and rake angle than a ball end milling cutter of the same diameter. This new type of milling cutter can solve the problems of low machining efficiency, severe tool wear, and low surface quality in titanium alloy processing. A comparison of the cutting performance of titanium alloys processed by the revolving cycloid milling cutter and the ball end milling cutter was carried out to obtain the variation laws of the cutting force and the processing surface quality under different tool wear conditions. The result shows that the wear zone of the revolving cycloid milling cutter is shallow and wide compared to that of the ball end milling cutter. As the wear speeds up, the spoon-shaped wear gathering zone found in the ball end milling cutter does not happen with the revolving cycloid milling cutter. The revolving cycloid milling cutter can significantly lower the axial force, the tangential force, and the ratio of the axial force to the tangential force with a stable cutting process.

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The effect of titanium alloy chemistry on machining induced tool crater wear characteristics

Cited by 33 publications

References 24 publications

An overview of conventional and non-conventional techniques for machining of titanium alloys

An overview of conventional and non-conventional techniques for machining of titanium alloys

Online Tool Wear Monitoring by the Analysis of Cutting Forces in Transient State for Dry Machining of Ti6Al4V Alloy

An Experimental Study on Milling Titanium Alloy with a Revolving Cycloid Milling Cutter

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