A novel magnetic field assisted diamond turning of Ti-6Al-4 V alloy for sustainable ultra-precision machining

Abstract

Titanium alloys play a crucial role in the advanced industries due to their high strength, resilience, rigidity, and low density, as well as their excellent corrosion resistance, which makes them suitable for a variety of engineering applications. Nonetheless, they have poor performance when machined. In this study, magnetic field diamond turning (MFDT) was used to increase the thermal conductivity and thus the machinability of machined Ti-6Al-4 V alloy parts, as well as the lifetime of the diamond cutting tool. The thermal properties of the work material under a magnetic field were investigated using ABAQUS software. The simulation results were validated by the cutting experiments, which demonstrated improved machining performance, increased tool life, and enhanced thermal properties of the machined parts. The surface morphology such as surface defects and surface roughness and microstructure modifications were investigated as evidence. This study demonstrates the effectiveness of the MFDT on the machinability of titanium alloys as the thermal conductivity increases, resulting in increased tool life and improved machined surface quality reached to more than 60% for achieving sustainable diamond machining.