This work comparatively studied the performances of straight cemented carbide tools and PVD coated carbide tools in high speed dry turning of Ti-6Al-4V alloy. Systematic machining tests have been performed and the tool life data were analysed using multiple linear regression method to establish extended Taylor tool life models. The wear mechanisms for both tools have been investigated in detail through SEM observation and X-ray energy dispersive microanalysis (EDS).
Increased wheel speed has been widely seen as a way to increase productivity with vitrified CBN. Chip thickness decreases as wheel speed is increased and in practice this leads to improved workpiece quality, higher G-ratios and reduced wheel costs. However, increasing wheel speed has implications for machine tool design. A machine tool has many natural frequencies. Increasing wheelspeed increases the risk of exciting one of these frequencies possibly leading to poor workpiece quality and reduced wheel life. Thus, care must be taken in the design of high-speed machine tools to reduce the risk of resonance occurring. A key question is, whether increased wheel speed justifies a more costly machine tool? This paper sets out to answer this question and to determine the importance of wheelspeed compared with other process parameters. The paper shows how each of the process parameters affect specific energy, surface roughness, roundness, size holding and G-ratio. This is achieved using direct effects charts generated from a two level experimental arrangement. The direct effects charts were validated from confirmation. The results show the direct effects charts to be an accurate guide for parameter level selection. The results show which parameters must be altered depending on whether improved workpiece quality or increased productivity is the priority. The work establishes that increased wheelspeed is the most important factor in achieving improved quality, wheel life and productivity. The research also shows suitable parameter levels for successful grinding of AISI 52100 using a vitrified CBN wheel.
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