Effects of shear thickening fluid preparation on tool performance in the milling of Ti6Al4V titanium alloy

Abstract

The performance and quality of tools can directly affect the efficiency and quality of machining, and preparation methods of the cutting edge have an important impact on the machining performance and tool life. As a method that can adapt to the unique and complex geometry of the cutting edge, shear thickening passivation is an innovative application of shear thickening fluid. In this study, the effects of shear thickening passivation methods on the milling performance and tool life of cemented carbide milling cutters were investigated. The cutting force, tool wear, tool life and surface morphology were analyzed by side milling Ti6Al4V titanium alloy with cemented carbide milling cutters that were unprepared, drag finished and shear thickening passivated, respectively. The results demonstrate that shear thickening passivation can remove the micro-defects of the tool after grinding. After shear thickening passivation, the cutting edge is rounded, and the rake and flank surfaces are flat, and the defects of the cutting edge are removed. Compared with the unprepared tool, the life of the shear thickening passivated tool is improved by 50 %. Therefore, the shear thickening passivation can effectively improve the tool life and tool performance and significantly reduce the economic cost in practical machining.