The effects of coolant on the cutting temperature, surface roughness and tool wear in turning operations of Ti6Al4V alloy

Abstract

The titanium alloys are widely used in aeronautical engineering and medical device materials due to exceptional mechanical properties such as tensile resistance and toughness of fractures. High thermo-mechanical loads occur in metal cutting of Titanium alloy Ti6Al4V, which can decrease life of cutting tool and increase cost of part production. In this paper, the coolant effects on the cutting temperature, surface roughness and tool wear are investigated by using the developed virtual machining system. The cutting forces during turning operations of Ti6Al4V alloy are accurately calculated in order to be used in calculation of cutting temperature and tool wear. The modified Johnson-Cook methodology is utilized to obtain the cutting temperatures along machining paths. Then, the Coupled Eulerian-Lagrangian (CEL) approach is investigated to predict and evaluate the effects of coolants on the cutting temperature in turning operations of Ti6Al4V alloy. The finite element approach is employed to predict tool wear by using the Takeyama-Murata analytical model and modifying the cutting tool geometry during the chip production process. To verify the developed methodology in the study, the results of experiments for the measured cutting temperatures, surface quality and wear rate are compared to the results of virtual machining system obtained by the finite element simulation. Thus, utilizing the proposed virtual machining system in the study, cutting temperatures, surface quality and tool wear during the turning operations of Ti6Al4V alloys with and without coolant can be accurately predicted to enhance the accuracy as well as productivity in the CNC machining operations.

Investigation of Microstructure, Mechanics, and Corrosion Properties of Ti6Al4V Alloy in Different Solutions

“…The wear characteristics of the Ti6Al4V alloy have been thoroughly Investigated In several research articles. The wear resistance of the Ti6Al4V alloy is affected by many elements, such as cutting pressures, chip shape, tool wear, sliding speed, surface improvement, and surface modifications [28][29][30]. The Ti6Al4V alloy may experience wear via many processes, such as abrasive wear, adhesive wear, corrosive wear, and oxidative wear [19,31].…”

“…The Ti6Al4V alloy may experience wear via many processes, such as abrasive wear, adhesive wear, corrosive wear, and oxidative wear [19,31]. The wear characteristics of the Ti6Al4V alloy may be influenced by several elements, including the friction coefficient, cutting temperature, surface roughness, and wear scar width [30,32,33]. Wear resistance is of utmost importance in biomedical applications, and researchers have examined the wear characteristics of the Ti6Al4V alloy in simulated bodily fluids [34].…”

Modification of CNC Machine Tool Operations and Structures Using Finite Element Methods: A Review

“…Soori and Arezoo [46]developed a virtual machining system application to examine whether cutting parameters affect tool life and cutting temperature during milling operations. Soori and Arezoo [47] studied the impact of coolant on the cutting temperature, roughness of the surface, and tool wear during turning operations with Ti6Al4V alloy. Recent developments from published papers are reviewed by Soori [48] in order to examine and alter composite materials and structures.…”