Abstract
Titanium alloys are widely used in the manufacture of aircraft and aeroengine components. However, tool wear is a serious concern in milling titanium alloys, which are known as hard-to-cut materials. Trochoidal milling is a promising technology for the high-efficiency machining of hard-to-cut materials. Aiming to realize green machining titanium alloy, this paper investigates the effects of undeformed chip thickness on tool wear and chip morphology in the dry trochoidal milling of titanium alloy Ti–6Al–4V. A tool wear model related to the radial depth of cut based on the volume of material removed (VMR) is established for trochoidal milling, and optimized cutting parameters in terms of cutting speed and axial depth of cut are selected to improve machining efficiency through reduced tool wear. The investigation enables the environmentally clean rough machining of Ti–6Al–4V.
Highlights
The application of titanium alloys has dramatically increased in many industries over the past half century, in the aviation and aerospace industries, where about 80% of titanium production is used [1]
To fill this research gap, this paper investigates the tool wear as well as the chip morphology in the dry trochoidal milling of titanium alloy Ti–6Al–4V based on a set of cutting experiments
There is a radial depth of cut corresponding to the lowest volume of material removed (VMR), which should be avoided in practical milling
Summary
The application of titanium alloys has dramatically increased in many industries over the past half century, in the aviation and aerospace industries, where about 80% of titanium production is used [1]. Li et al [23] investigated the effect of high cutting speed on tool wear in the dry milling of Ti–6Al–4V, and found that the increase in the cutting speed and feed rate accelerated the tool wear and drastically decreased the tool lifetime. Trochoidal milling is a promising technology for the high-efficiency machining of hard-to-cut materials This method is a combination of circular milling and slicing [26], which possesses a small engagement region between the tool and workpiece, and enables a relatively high feed rate and axial depth of cut to increase the machining efficiency. To fill this research gap, this paper investigates the tool wear as well as the chip morphology in the dry trochoidal milling of titanium alloy Ti–6Al–4V based on a set of cutting experiments. A set of optimized cutting parameters for the dry trochoidal milling of Ti–6Al–4V was selected and validated by cutting experiments
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