Abstract
The machining of titanium alloys always raises issues because of their peculiar chemical and physical characteristics as compared to traditional steel or aluminum alloys. A proper selection of parameters and their monitoring during the cutting operation makes it possible to minimize the surface roughness and cutting force. In this experimental study, infrared thermography was used as a control parameter of the surface roughness of Ti6A4V in dry finish turning. An analysis of variance was carried out to determine the effect of the main cutting parameters (cutting speed and feed rate) on the surface roughness and cutting temperature. In the examined range of the machining parameters, cutting speed and feed were found to have a primary effect on the surface roughness of the machined parts. Cutting speed also significantly affected the temperature of the cutting region, while feed was of second order. Higher cutting speeds and intermediate feed values gave the best surface roughness. A regression analysis defined some models to relate the cutting temperature and surface roughness to the machining parameters. Infrared thermography demonstrated that the cutting temperature could be related to roughness.
Highlights
In recent years, dry machining has had an increasing role in cutting operations to cope with more severe environmental regulations and to reduce the costs of lubricant fluids
A proper selection of parameters and their monitoring during the cutting operation makes it possible to minimize the surface roughness and cutting force. In this experimental study, infrared thermography was used as a control parameter of the surface roughness of Ti6A4V in dry finish turning
An analysis of variance was carried out to determine the effect of the main cutting parameters on the surface roughness and cutting temperature
Summary
Dry machining has had an increasing role in cutting operations to cope with more severe environmental regulations and to reduce the costs of lubricant fluids. The high temperatures that can be reached at the tool/workpiece interface have a harmful influence on the surface quality of machined parts; for instance, owing to excessive tool wear or metal oxidation For these reasons, the dry machining of Ti6Al4V is normally a prerogative of finishing operations, which can allow the obtaining of proper surface roughness without lubricants through the use of coated tool inserts. The real-time monitoring and assessment of cutting temperature through infrared thermography is a promising solution to automate machining and predict the surface quality of machined parts This system uses thermal cameras to detect the temperature field generated during the cutting operation to evaluate the influence of machining parameters (such as cutting speed, feed, depth of cut, and tool geometry) on friction at the tool/workpiece interface, as well as on tool wear and surface roughness. The monitoring of the maximum temperature could be used to predict the surface roughness of the machined part and to prevent improper cutting conditions such as those caused by excessive tool wear
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