Abstract
Aerospace titanium components are manufactured under the strictest standards in order to ensure the highest quality. To develop highly efficient machining processes, extensive research and investment is necessary. For the specific case of rotating titanium critical components, large quantities of forged workpieces are machined to determine the effects of the different machining parameters on tool wear characteristics and component structural integrity and performance. However, testing the different permutations of metal removal parameters and tool combinations is expensive and time consuming at the development stage. The novel approach developed and presented here, enables the machining of smaller titanium parts that can be compared 1-to-1 to parts extracted from industrial machined disc components. This approach not only reduces cost, but ultimately accelerates the research and development process due to more rapid feedback between different iterations of the machining parameters. The proposed technique specifically replicates the face turning operation performed in rotational critical titanium components, such as compressor discs, using small coupons machined in a standard CNC machining centre. The machined coupons can be fatigue tested through a 4-point bending and microstructural analysis can be performed on the tested coupons to directly study the effects of the machining process on the surface and underlying microstructure.
Highlights
This paper presents a novel approach that replicates expensive and time-consuming face turning machining operation of disc profiles
The implementation of this technique will reduce research and development costs and provide the ability to test a wider range of development titanium alloys, machining parameters and development tools at an early stage
The same machining conditions have been achieved on small titanium alloy coupons, using the same machining parameters and material removal rate
Summary
This paper presents a novel approach that replicates expensive and time-consuming face turning machining operation of disc profiles. The proposed technique developed at The University of Sheffield uses small coupons on a standard CNC milling machine. This enables the rapid assessment of machining and tooling parameters on subsurface damage and fatigue performance. Titanium alloys are widely regarded as difficult to machine, due to their excellent mechanical properties at high temperatures, low thermal conductivity and high chemical reactivity [1]. This leads to very expensive machining costs, which can account for up to 60% of the total cost of the component and disproportional tool wear. It is estimated that more than 37000 new commercial planes (with more than 100 seats) will be required by 2037
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