Abstract
When milling titanium alloy, the cutting temperature has a strong impact on the degree of tool wear and, in turn, tool life and the surface quality of the workpiece. The distribution of the temperature field on a tool’s rake face can be improved through the use of micro-textures, which help to reduce friction and, ultimately, wear on the tool. In this paper we present a new way to measure cutting temperature and examine heat distribution when milling titanium alloy with micro-textured ball-end milling tools. We first establish the heat flux density function for the contact area between the workpiece and the tool and then for the rest of the tool. Thermal stress simulation shows that adhesive wear tends to happen in the contact area and on the flank face, rather than at the tip of the tool, with the temperature distribution gradient for the rest of the tool being more uniform. The maximum value for thermal stress on the cutting edge was 2.0782 × 106 Pa. This decrease as you move away from the cutting edge along the contact area between the tool and the workpiece. Maximum deformation of the tool is also mainly concentrated at the principal contact point, with a value of 1.9445 × 10−9 m. This, too, decreases as you move away from the cutting edge and into the rest of the contact area. This research provides the basis for the optimization of tool structure and further investigation of the thermo-mechanical coupling behavior of micro-textured ball-end milling cutters when milling titanium alloy.
Highlights
In titanium alloy milling processes, a key cause of cutting tool failure is adhesion-based wear on cutting tool surfaces
The specific objective here was to arrive at a principled way of calculating the relationship between heat and the cutting cycle. With this in hand we were able to simulate the heating of the rake face of a micro-textured ball-end milling tool that we could compare to the experimental data and the derived theory
If we ignore any power in the third deformation zone and focus just on the cutting power for titanium alloy consumed by the first and second deformation zones, the temperature field for the tool-chip contact area can be worked out from the known heat sources
Summary
In titanium alloy milling processes, a key cause of cutting tool failure is adhesion-based wear on cutting tool surfaces. On the basis of this, they established a method for calculating fluctuating temperature fields and theoretically deduced the temperature distribution on the contact surface at the point where the tool cuts into and out of the workpiece. This has had a very important influence on studies of tool life and tool damage. The primary objective of this work concentrates on the optimal selection of milling parameters (cutting speed (vc), surface inclination angle α), which enables the simultaneous minimization of cutting force values and increased process efficiency This procedure is carried out with the application of the response surface method, based on the minimization of a total utility function. The results of this analysis can be used to inform the future optimization of cutting tool structures and provide useful input for the ongoing study of the thermo-mechanical coupling behavior between cutting tools and difficult to cut materials
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