A Study on the Cutting Characteristics and Detection of the Abnormal Tool State in Turning of Ti-6Al-4V ELI

Abstract

The cutting characteristics of biomaterials (Ti-6Al-4V ELI) by tools are investigated with respect to cutting force, work piece surface roughness and tool flank wear by the vision system. Ti-6Al-4V ELI titanium turning is carried out with various cutting conditions; spindle rotational speed and feed rate. Back propagation neural networks (BPNs) are used for detection of tool wear. The input vectors of neural network comprise of spindle rotational speed, feed rates, vision flank wear, and cutting force signals. The output is the tool wear state which is either usable or failure. The detection of the abnormal states using BPNs achieves 97.5% reliability even when the spindle rotational speed and feed rate are changed.

Investigation on surface roughness, tool wear and cutting power in MQL turning of bio-medical Ti-6Al-4V ELI alloy with sustainability

“…Ti and Ti alloys are the most favorable bio-materials for dental implants and orthopedic implants. 1 As such implants are utilized for a short or long period or even permanent, hence the bio-materials must have appropriate surface quality, strength, bio-compatible with bones and tissues, excellent corrosion resistance and reliable chemical stability. Ti-alloys (Grade 23 and Grade 5) are the most extensively used metals for the manufacturing of orthopedic equipment, implants and surgical devices for medical fields; therefore it is a prime requirement to have reasonably good surface characteristics (lower surface roughness, damage-free surface, etc.)…”

“…but it has limitations like poor thermal conductivity and highly reactive at elevated temperature, etc., which makes it difficult to machine. 1,2,8,9,14,18 To overcome the above difficulties, the application of inexpensive multi-layer coated carbide cutting tool in machining Ti-6Al-4V ELI alloy is proposed in this paper because of superior properties of lubricating, thermal barrier and wear-resistant thus can protect the cutting tool wear and may enhance tool life. Very limited work has been noticed for machining investigation of Ti-6Al-4V ELI alloy till date.…”

Machining of Ti-6Al-4V ELI Alloy: A brief review

“…When machining at excessive cutting speed more heat appeared at cutting region due to low thermal conductivity causes of the rise in the temperature at a cutting zone which affected the performance of the cutting insert and the quality of the finished machined surface [2,3]. Tool wear is affected the overall machining performance.…”

“…The performance of the uncoated carbide insert is low in the dry cooling condition. Shin et al [3] used Back propagation neural networks technique for detecting the wear at cutting edge and the effect of the input parameters when turning of Ti-6Al-4V ELI in dry condition used CVD coated cemented carbide tool insert. Found that the surface roughness has closed relationship with tool wear.…”

“…Because when working in dry environment more heat engendered at the cutting area which causes of tool wear to eliminate this problem using a suitable cooling condition which is harmless for the environment and employed health such as MQL, Cryogenic etc. cooling condition [3,5]. Sulaiman et al [2] predicted the optimized cutting variables during turning of the Ti-6Al-4V ELI under wet cooling environment using RSM technique.…”