Titanium alloys are widely used in aerospace industries, due to its high strength to weight ratio and light weight. This paper investigates high speed end milling of titanium alloy (Ti-6% Al-4% V) using carbide insert based end mill cutter. Effects of cutting forces during high speed machining of titanium alloys have got higher attention in selecting the optimal cutting conditions to improve the production and tool life. Due to Titanium alloy's low thermal conductivity, more heat concentration takes place on cutting tool during rough machining. The heat generated increases the temperature of the cutting tool and affect the surface integrity of the workpiece and also cause tool wear. In this study experiments have been carried out under dry cutting conditions. The cutting speeds selected for the experiments are 120, 150 and180 m/min. The depth of cuts and feed rate were selected to suit finish machining. For conducting the experiments single insert based cutting tool is used. Experiments were conducted based on the Taguchi's design of experiments, in order to analyse the effect of cutting parameters on cutting force, temperature and surface roughness. From this study it is found that depth of cut and feed rate have higher effect on cutting forces when compared to cutting speed whereas the effect of cutting speed has higher effect on temperature.
A novel approach of a gas pressure infiltration technique is presented for the synthesis of Co-Continuous Ceramic Composite (C4). SiC foams of varying pore sizes were infiltrated with aluminium AA5083. Optical examination revealed that the SiC foams contained open cells with a network of triangular voids. The number of pores-per-inch (PPI) in the foams was found to depend on the strut thickness and pore diameter. The compressive strengths of two foam configurations, 10 and 20 PPI, were estimated to lie between 1–2 MPa. After infiltration, the compressive yield strength of the resulting C4 was observed to increase to 126 MPa and 120 MPa, respectively, for the 10 and 20 PPI C4. Additionally, the infiltration of ceramic foam with the AA5083 alloy resulted in an increase in strength of 58–100 times when compared with plain ceramic foam. The failure modes of the composites in compression were analyzed by crack propagation and determining the type of failure. The study revealed that shear failure and vertical splitting were the predominant mechanisms of compression failure, and that the fabricated C4 is advantageous in mechanical properties compared to the plain ceramic foam. This study, therefore, suggests the use of C4 composites in armour applications.
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