Identifying Optimal Cutting Parameters in Drilling of Titanium Aluminum Vanadium Using Finite Element Analysis

M M Reddy,N S Reddy,S R Kostka

doi:10.4236/jsemat.2020.103004

Abstract

Titanium alloys are widely used in the aerospace industries because of their excellent strength-to-weight ratio, high resistance to corrosion, high chemical reactivity and low thermal conductivity and ability to withstand high temperatures. However, these properties make titanium alloys difficult to machine. Drilling of titanium alloy may generate high temperature and high cutting forces. This paper is aimed at determining the suitable cutting parameters in the drilling of titanium alloys to minimize the cutting temperature and cutting forces. A finite element 3D model of the drilling process is simulated in this research. A combination of drilling speeds and feed rates are simulated to obtain the resulting responses of cutting force and temperature. The central composite design (CCD) is used to generate different combinations of cutting parameters to reduce the number of experiments and optimize the temperature and cutting force responses. Results show at the drilling speed of 5000 rpm with a feed rate of 0.1 mm/rev, temperature and cutting force significantly reduced.

Highlights

Titanium is known to be very difficult to machine, despite its excellent properties and wide usage
The heat generated while machining does not dissipate because of the weak thermal conductivity and this will cause a definite reduction in tool life
It is important to participate in contributing research to identifying important parameters in drilling of Titanium and further optimize it as Titanium has shown to be thriving in aerospace industry, and continues to gain favor when it comes to the choosing of materials

Summary

Introduction

Titanium is known to be very difficult to machine, despite its excellent properties and wide usage. Experimental work was conducted by Sultan et al [5] to identify the optimum cutting speed and feed rate for discontinuous chip formation with a drilling process. The influence of cutting parameters such as cutting speed, feed rate are considered to estimate the cutting force and cutting temperature. These parameters were tested and optimized using Response Surface Methodology with the Design Expert. The research performed here is aimed at reducing the cutting temperature and cutting force which is pre-determined by the parameters tested to further improve cost and machining efficiency with regards to tool life and workpiece surface integrity. This research looks to determine the utmost optimal parameters for Titanium drilling that can be used as reference in all future drilling activities of the Titanium material

Objectives

Methods

Conclusion