Tool wear in disk milling grooving of titanium alloy

Abstract

The work efficiency of grooving machining can be improved by the approach of disk milling. However, the problem of tool wear was serious because of big milling force and high milling temperature in manufacture process, by which the tool life and the machined surface quality were influenced. In this study, disk-milling grooving experiments of titanium alloy were designed and conducted. First, milling force and milling temperature were examined, which provided theory basis to tool wear. Then, the tool life, wear patterns, and its corresponding mechanisms were investigated in detail through scanning electron microscope observation, X-ray energy-dispersive spectrometer, and automatic tool analyzer. By analyzing experimental results, it was found that, for an example of five-stage compressor blisk of a certain type aircraft engine, disk cutter can only remove about 50 tunnels' volume after five times grinding before wear-out failure, the tool life still needs to be greatly enhanced. The damage morphologies were delamination, thermal fatigue crack, plastic deformation, and tipping. Wear mechanisms were the synergistic interaction among adhesion wear, oxidation wear, and diffusion wear. Thermal crack and tipping were easily found for the cutting edges around the keyway. The oxidation degree of major cutting edge was higher than minor cutting edge; rake face was severe compared to flank face. The element W easily diffused into the titanium alloy, the diffusion ability of Co and C were weaker than W, and the element Ti was dead in diffusion process.

Tool wear prediction model based on wear influence factor

“…As an efficient roughing method, disc milling has the characteristics of high cutting force and high cutting temperature [16] [17]. Therefore, compared with ordinary milling, the tool wear rate of disc milling is faster, especially in the case of poor cooling.…”

“…7. According to the cutting and wear mechanism [17] [18], tool wear is positively correlated with cutting temperature and cutting force. If the feed per tooth p a is increased while the cutting line speed V remains constant, both the cutting force and the cutting temperature will increase.…”

Application of Adaptive Materials and Coatings to Increase Cutting Tool Performance: Efficiency in the Case of Composite Powder High Speed Steel

“…The semiartificial clamped microthermocouple method was used [82] to study the temperature fields in the cutting wedge of the tool. Composite plates of various tool materials were used, divided by the main intersection plane (cutting edge normal plane) into two parts, tightly (without a gap) compressed by pins before sharpening, excluding the possibility of their relative displacement to lay semiartificial microthermocouples.…”

Identification of eccentricity for disc milling cutter of indexable two sided inserts

“…This method needs many iterations and the calculation is not simple enough. Xin et al [25][26][27] and Zhang et al 28 proposed a new method to remove the large margin of blisks channel by disc milling cutter instead of ball-end milling cutter or plunge milling cutter. Zhang et al 28 presented a theoretical force model for the milling method, but the cutting force coefficients are difficult to identify.…”