Abstract
The paper details the performance of a range of polycrystalline diamond (PCD) tools (∼1.3–39μm average diamond grain size) when turning Ti–6Al–2Sn–4Zr–6Mo with 150bar cutting fluid. The alloy is used for aeroengine components such as turbine discs due to its superior mechanical and elevated temperature properties. Tool life improved from ∼30 to 80min with increasing grain size except with the ultra-coarse (∼39μm) PCD grade, which failed via chipping/edge fracture after ∼8min. In general, the principal wear modes were crater formation and workpiece adhesion. Workpiece integrity assessment showed no major subsurface damage with surface compressive residual stresses of ∼600MPa.
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