Abstract
This paper reports a fundamental investigation consisting of systematic trials into the response of Ti6Al4V alloy to high-speed machining using carbide inserts. It is a useful extension to work previously published, and aims at assessing the impact of the process parameters, depth of cut, cutting speed and feed rate in addition to cutting length, and their interrelations, on observed crater and flank wear and roughness of the machined surface. The results showed that abrasion was the most important flank wear mechanism at high speed. It also showed that increased cutting length accelerated crater wear more than exhibited flank wear and had considerable effect on surface roughness. In particular, crater wear increased by over 150% (on average), and flank wear increased by 40% (on average) when increasing cutting length from 40 to 120 mm. However, cutting the same length increased surface roughness by 50%, which helps explain how progression of tool wear leads to deteriorated surface quality. ANOVA was used to perform statistical analyses of the measured data and revealed that cutting length and depth of cut had the greatest effect on both crater and flank wear of the cutting tool. These results confirm that high-speed machining of Ti6Al4V alloy is a reliable process, with cutting speed identified as having a relatively small influence on the tool wear and resultant roughness of the machined surface relative to other parameters.
Highlights
Abbas et al [30,31] achieved their goal over a wide range of machining conditions, they did not provide an adequate explanation of their results. This has motivated the authors of this investigation to attempt to bridge this gap and address this omission because as revealed by the literature search, high-speed machining of titanium alloys remains problematic and more studies are needed to optimize both cutting tool selection and cutting conditions to minimize tool wear while maintaining good surface quality, without increasing manufacturing costs
The measured data for surface roughness (Ra), crater wear (KB ), and flank wear (VB ) for given values of cutting speed, depth of cut and feed rate, and for cutting length values of 5, 40, 80, and 120 mm are illustrated in Figures 1–4, respectively
Comparing the results for different values of cutting length, we see crater wear increased by over 150%, and flank wear increased by 40% when increasing cutting length from 40 to 120 mm
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. Silva et al [21] used different types of cutting inserts when high-speed machining Ti6Al4V and found for cutting speed between 240 and 300 m·min−1 , PCD inserts gave much better wear than cemented carbide inserts The latter gave acceptable results only in the range. Abbas et al [30,31] achieved their goal over a wide range of machining conditions, they did not provide an adequate explanation of their results This has motivated the authors of this investigation to attempt to bridge this gap and address this omission because as revealed by the literature search, high-speed machining of titanium alloys remains problematic and more studies are needed to optimize both cutting tool selection and cutting conditions to minimize tool wear while maintaining good surface quality, without increasing manufacturing costs. This paper aims to extend the investigation reported in [30,31] to understand how the various machining factors and their interactions affect surface roughness, flank wear, and crater wear (KB ) when high-speed machining titanium alloys, in particular Ti6Al4V
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