Abstract
This paper presents a multi-factorial approach to the tool wear evolution when machining Ti6Al4V titanium alloy using high temperature resistant AlTiN coated cutting tools. Machining conditions were selected based on the technological database of machining titanium alloys in aircraft plants. The main novelty of this study is that tool wear progress within the tool life of about 20 min is assessed integrally in terms of mechanical, thermal and tribological process outputs such as cutting forces, cutting energy and cutting temperature. Moreover, the specific cutting energy (SCE), thermal softening effect and friction coefficient (CoF) were determined when recording tool wear curves. Some important research findings concerns distinguishing the three characteristic wear periods with distinctly different values of SCE and CoF. In particular, it was revealed that the formation of ceramic protective layer (CPL) on the AlTiN deposited coating influences friction and the tool wear mechanism.
Highlights
At present titanium and nickel-based alloys, termed heat resistant superalloys (HRSAs) represent a significant percentage of construction metallic materials used in the aircraft structural and engine components [7, 9, 15]
The cutting speed of 150 m/min should be recommended for aerospace practice because it guarantees the economic tool life of Te=20 min and further analyses were performed for this cutting speed
This study clearly explained the influence of tool wear on friction modification resulting from thermal effects including thermal softening, increase of thermal diffusivity and the formation of protective ceramic layer
Summary
At present titanium and nickel-based alloys, termed heat resistant superalloys (HRSAs) represent a significant percentage of construction metallic materials used in the aircraft structural and engine components [7, 9, 15]. In contrast to their attractive mechanical and physical properties their machinability rates are poor in terms of both productivity (short tool-life) and technological quality or surface integrity criteria [3, 7, 9, 11]. Earlier author’s study concerning the (*) Tekst artykułu w polskiej wersji językowej dostępny w elektronicznym wydaniu kwartalnika na stronie www.ein.org.pl
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