Machining Process Of Titanium Alloy Research Articles

Pemesinan Paduan Ti-6Al-4V ELI

Titanium alloy material Ti-6Al-4V ELI (Extra Low Interstitial) is a type of alloy that has very similar properties to Ti-6Al-4V (Grade 5) alloy, which is the most widely used material, but only differs in terms of properties. his tenacity. Ti-6Al-4V ELI has higher ductility and better fracture toughness. In addition, this material also has a good ability to work at high temperatures without losing its main properties. The main properties of this material are corrosion toughness at high temperatures and excellent weight to strength ratio. Referring to these advantages, the alloy material of the Ti-6Al-4V ELI type has been developed in many fields including the field of planting materials in the medical field, the aircraft industry, applications in the field of military weapons, the manufacture of racing vehicle components and also high pressure vessels for storing materials. low-temperature (cryogenic) liquid nitrogen [16].. During the machining process of titanium alloy, many things become obstacles because this material is a material that is difficult to machine. This is because the titanium alloy has high hardness, there is often a reaction between the cutting tool and the workpiece material during the cutting process, and there is an accumulation of high temperatures in the cutting area. Factors cutting speed and feed rate are the two dominant factors on the formation of cutting tool wear, both wear on the face or crater side. Damage to the cutting tool is also followed by damage to the surface of the workpiece being machined or the surface quality of the workpiece. The dominant wear that occurs in the rib face area is wear due to adhesion, notch wear, while wear in the crater area is diffusion that occurs during the machining process. Meanwhile, the cutting temperature has a direct impact on the surface quality of the workpiece being machined. The factor of high cutting speed with low feed rate is a combination of factors that provide good cutting force. Meanwhile, insert type cutting tools that have a hard coating, such as TiN, TiAlN and TiCrN play a significant role in the formation of tool wear. Likewise, hard coated tools provide better performance compared to uncoated insert tools. Machining with the Minimum Quantity Lubrication (MQL) method gives better results compared to dry machining and machining using flooded cooling.Keywords: machining, Ti-6Al-4V ELI, cutting tool, materials.

Experimental research on milling of TC11 by scCO2-MQL and edge morphology

Titanium alloy is widely used in typical aerospace structural parts because of its excellent mechanical properties and corrosion resistance. However, the serious problem of tool wear in the machining process of titanium alloy often leads to the decline of machining quality. In this article, scCO2 MQL cutting experiment and dry cutting experiment of TC11 are carried out. The machined surface morphology, plastic deformation, residual stress and tool wear were analyzed. The results show that scCO2 MQL can effectively reduce the surface defects on the machined surface. The increase of cutting edge structure and blunt radius of the composite increases the plastic deformation degree of the material, as well as the residual stress and work hardening degree. The scCO2 MQL can effectively improve the cutting contact area and reduce tool joint wear.

Novel hybrid machining process of titanium alloy for texturing high-quality microstructure array surfaces

Titanium alloys are widely applied in the aerospace field, such as nacelle and landing gear. As the typical difficult-to-machining materials, generating microstructure arrays with high quality on their surfaces still face a challenge. For solving this problem, this study proposes a novel hybrid machining process to texture microstructure arrays on titanium alloy surfaces. In this hybrid machining process, laser-assisted diamond turning is used to improve machinability by softening material surfaces, and slow-tool-servo cutting is used to generate various microstructure arrays. Experimental results showed the sine-shaped and honeycomb-shaped microstructure arrays were smoothly generated on the titanium alloy surfaces. The average machining error is lower than 3 %, which demonstrates the high machining accuracy of the hybrid machining process. The surface roughness (Sa) is lower than 30 nm, which demonstrates the high surface quality. Besides, the phase change and grain size are also in-detailed investigated to analyze the effects of the proposed hybrid machining process on the workpiece material. This study provides an efficient and flexible machining method to texture microstructure arrays on titanium alloy surfaces, which can be directly applied to surface modification of industrial production.

Evaluation of the tool wear in the turning process of INCONEL 718 using PCD tools

The use of nickel-based alloys (superalloys) has an ever-growing demand because of the combination of mechanical properties and corrosion resistance even at relatively high temperatures. Those same properties, however, increase the challenge to increase the cost-benefit of the machining operations. Nickel superalloys are usually machined using coated cemented carbide inserts at relatively lower cutting speeds or ceramic inserts at higher cutting speeds. The use of PCD tools, despite widespread at the machining process of titanium alloys, regarding the machining of nickel-based alloys has almost no research data, especially for Inconel. This happens mostly because of the alloys’ iron content leading to graphitization of the diamond at the tool. This paper presents a study about the viability of PCD tools in the turning process of Inconel 718 in finishing conditions. The machinability was assessed under different tool rake angles, cutting speeds, feed rates, and minimum lubrication flow rates. The results were compared regarding the specific cutting pressure, average workpiece profile roughness, tool wear and wear mechanisms observed through electronic microscopy. The results indicate that the rake angle did not have a statistically significant influence for the evaluated machining conditions and the feed rate was the most significant parameter, as it is linked with the specific cutting pressure and workpiece roughness. Adhered material seemed to have protected the rake surface from attrition, which reduced the amount of wear particles that promote abrasion of the flank surface. However, the increase in MQL flow seems to destabilize the adhered material and promote more severe wear. Overall, microchipping and adhesion were the most important wear mechanisms.

Development of a model for the optimization of energy consumption during the milling operation of titanium alloy (Ti6Al4V)

The quest for improvement in the cost effectiveness, environmental friendliness and the energy efficiency during the machining process of titanium alloy has necessitated the use of numerical and physical experimentations for the optimization of energy consumption. The Response Surface Methodology (RSM) was employed for the numerical experimentation with the process parameters in the following range; cutting speed (250–270 mm/min), feed rate (0.05–030 mm) and axial depth of cut (0.50–3.0 mm). The physical experiments were investigated using a DMU80monoBLOCK Deckel Maho 5-axis CNC milling machine with a spindle speed of 1800 rpm. A mill cutter (SF550: HRC 40-HRC 50) was employed for the cutting operation while a KISTLER dynamometer (9257A 8-Channel Summation of Type 5001A Multichannel Amplifier) with the data acquisition system was used for the cutting force measurement. Using the 2FI model, the statistical analysis of the results obtained produced a mathematical model which correlates the process parameters as a function of the specific cutting energy. The results obtained show that the specific cutting energy, cutting speed and depth of cut increases with a decrease in feed rate. The findings of this work will assist manufacturers in the energy optimization and conservation during the machining operation of titanium alloy.

Process design and modelling for milling operation of titanium alloy (Ti6Al4V) Using the Taguchi method

Abstract The right combination of the process parameters that will bring about effective milling operation of titanium alloy (Ti6Al4V) is a critical decision which requires scientific basis for its justification. In this work, the Taguchi method involving four factors and three levels was employed for the process optimization during the milling operation of Ti6Al4V. The physical experiments were performed using the DMU80monoBLOCK Deckel Maho 5-axis CNC milling while a stationary dynamometer (KISTLER 9257A 8-Channel Summation of Type 5001A Multichannel Amplifier) was employed for data acquisition in real time. The range of the process parameters employed include: cutting speed (250000-270000 mm/min), feed per tooth (0.02-0.05 mm), axial depth of cut (0.50-3.0 mm) and radial depth of cut (0.06-5.00 mm). Taking the rate of material removal as the response of both the numerical and physical experiments, the statistical analysis of the results obtained produced a mathematical model for the optimization of the process parameters and the rate of material removal during the milling operation of titanium alloy. The optimization produced 81 solutions whose desirability equals to 1 and the optimum values of the process parameters which produced the highest rate of material removal (40935.3 mm3/min) were: speed (260,000 mm/min), feed per tooth (0.03 mm), axial depth of cut (1.50 mm) and radial depth of cut (2.80 mm). The findings of the work will assist the manufacturing industries in the process design, modelling and optimization of the machining process of titanium alloy.

Study on the Design and Cutting Performance of a Revolving Cycloid Milling Cutter

Problems such as low machining efficiency, severe tool wear and difficulty in safeguarding surface quality always exist in the machining process of titanium alloy with ball-end milling cutters. To address these issues, the design and manufacture of a revolving cycloid milling cutter for titanium alloy processing were studied in this paper. Firstly, the mathematical model of the revolving cycloid milling cutter contour surface was established. The parametric equation of an orthogonal helix cutting edge curve of a revolving cycloid milling cutter is presented. Then, the bottom boundary curve of the rake face is introduced. The five-axis grinding trajectory equation of revolving cycloid milling cutter rake face was derived based on the edge curve equation and coordinate transformation. Next, fabricating the revolving cycloid milling cutter and detecting the grinding accuracy of tool profile and geometric angle were performed. At last, a contrast test regarding the performance of the revolving cycloid milling cutter and the ball-end milling cutter in cutting titanium alloy TC11 was carried out. According to the test results, in comparison to the ball-end milling cutter, the revolving cycloid milling cutter had a smaller ratio of the axial force to the tangential force. Moreover, its flank face wore more slowly and evenly. As a result, a good surface processing quality can be maintained even under larger wear conditions, demonstrating an outstanding cutting performance.

Application of minimum quantity lubrication techniques in machining process of titanium alloy for sustainability: a review

Recently, the manufacturing sector is increasingly keen to apply sustainability at all levels of sustainability from system to products and processes. At the processes level, cutting fluids (CFs) are among the most unsustainable materials and need to be addressed properly in accordance with three main and decisive aspects, also known as the triple bottom line: ecology, society, and economics. Minimum quantity lubrication (MQL) is a promising technique that minimizes the use of CFs, thus improving sustainability. This paper presents a review of the literature available on the use of the MQL technique during different machining processes involving titanium alloys (Ti-6Al-4V). To carry out the study, four search engines were used to focus on the most cited articles published over a span of 17 years from 2000 to 2016. The performance and drawbacks are compiled for each eco-friendly technique: dry, MQL, and cryogenics with combinations of MQL and cryogenics, critically considering machining parameters such as cutting speed, feed rate, and output measures, namely surface roughness, tool life, and cutting temperature. After drawing conclusions from critical evaluation of research body, future research avenues in the field are proposed for the academics and industry.

On the Physics of Machining Titanium Alloys: Interactions between Cutting Parameters, Microstructure and Tool Wear

The current work deals with the analysis of mechanisms involved during the machining process of titanium alloys. Two different materials were chosen for the study: Ti-6Al-4V and Ti-55531. The objective was to understand the effect of all cutting parameters on the tool wear behavior and stability of the cutting process. The investigations were focused on the mechanisms of the chip formation process and their interaction with tool wear. At the microstructure scale, the analysis confirms the intense deformation of the machined surface and shows a texture modification. As the cutting speed increases, cutting forces and temperature show different progressions depending on the considered microstructure (Ti-6Al-4V or Ti-55531 alloy). Results show for both materials that the wear process is facilitated by the high cutting temperature and the generation of high stresses. The analysis at the chip-tool interface of friction and contact nature (sliding or sticking contact) shows that machining Ti55531 often exhibits an abrasion wear process on the tool surface, while the adhesion and diffusion modes followed by the coating delamination process are the main wear modes when machining the usual Ti-6Al-4V alloy.

Simulation machining of titanium alloy (Ti-6Al-4V) based on the finite element modeling

Titanium alloy is the most significant material used in the aviation industry because of their properties such as high strength and corrosion resistant. However, it is considered one of the most challenging areas for all industrialists due to their poor machinability. Therefore, machining process needs to be controlled by selecting the optimal cutting conditions to obtain the best machining responses at the same time which is very difficult and involves high cost. Hence, this review paper presents the investigation of an agreement between the simulation results and experimental findings to evaluate the finite element modeling (FEM) for prediction of the machining parameters of titanium alloy (Ti-6Al-4V). Computer-aided engineering tools, especially software which was used to perform the simulation. Four types of finite element software have been focused during the machining process of titanium alloy (Ti-6Al-4V) such as AdvantEdge, ABAQUS/EXPLICIT, DEFORM, and FORG software. The simulation results of FEM proved an agreement with the experimental data during the machining process of titanium alloy (Ti-6Al-4V). The FEM permits to reduce the cost of manufacturing in terms of prolonging the cutting tool life and saving machining time.

Finite element modelling to predict cutting parameters for milling on titanium alloy (Ti-6Al-4V)

Finite element modelling (FEM) is considered a very important tool for estimating the cutting forces and stress-strain analysis because it can produce very accurate results, minimise the costs of manufacturing, and machining time saving as well. The present work predicts the cutting parameters by FEM after conducting the experimental process of titanium alloy (Ti-6Al-4V) by using a face milling operation. In addition, finite element modelling has been proven in simulation of titanium alloy (Ti-6Al-4V) dry cutting. The experimental tests were performed at several axial depths of cut while the feed rate and cutting speed remained constant. The test results led to the conclusion that the axial depth of cut directly affects cutting parameters during the machining process of titanium alloy (Ti-6Al-4V) and thus surface finish during production. The effects on cutting force components are more obvious than on stress and strain components. Besides that, it was found that the axial depth of cut affects the main cutting force more than the feed cutting force.

Control of Machining Process for Titanium Alloy Based on Green Cooling and Lubricating Technology

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. The cutting experiments are carried out based on green cooling and lubricating technology. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface. And it can help to chip forming and breaking. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy.

Machining Process of Titanium Alloy Based on Green Cooling and Lubricating Technology

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface appearance. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy instead of cutting floods.