Titanium alloys are widely used in aeronautics that demands a good combination of high strength, good corrosion resistance and low mass. The mechanical properties lead to challenges in machining operations, such as high process temperature as well as rapidly increasing tool wear. In this work, three carbide end mills have been used in machining of titanium alloy Ti-6Al-4V. The first tool is coated with TiAl; the second and the third are coated with multi-layers or with a single layer of TiAlN. The cutting force and the tool life have been experimentally investigated and put into relationship with the process parameters under dry cutting condition. The quality of the machined surfaces has been evaluated by measuring the roughness of the machined surfaces. Finally, the correlation among cutting force variation, tool wear propagation and surface roughness has been analyzed and discussed. These three tools demonstrate to be able to maintain their hardness and other mechanical properties at the high cutting temperatures that they encountered.
Stone machining by diamond tool is a widespread process to manufacture both standard products, such as tiles, slabs, kerbs, and so on, and design shapes. Cutting force and energy may be used to monitor stone machining. Empirical models are required to guide the selection of cutting conditions. In this paper, the effects of cutting conditions on cutting force and cutting energy are related to the shape of the idealized chip thickness. These effects are put into relationship with the diamond tool wear too. The empirical models developed in this paper can be used to predict the variation of the cutting energy. Therefore these models can be used to guide the selection of cutting conditions and to predict when it is needed to change the tool. The chip generation and removal process has been quantified with the intention of assisting both the toolmaker and the stonemason in optimizing the tool composition and cutting process parameters, respectively.
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