Cutting responses of additive manufactured Ti6Al4V with solid ceramic tool under dry high-speed milling processes

Titanium alloys have been extensively used in practical machining owing to their outstanding mechanical properties, high specific strength and low thermal deformation. In this study, the cutting experiments are carried out on Ti6Al4V material with right-hand and straight cemented-carbide groove reamers. The experimental results show that the cutting force with the right-hand reamer is smaller compared to straight groove reamer due to the groove structure. The main tool wear forms are micro-chipping, adhesive wear, abrasive wear, and coating falling off on the right-hand reamer, while there is a built-up edge and serious damage failure on the cutting edge of the straight groove reamer. Notch wear and pitting on the surface of the hole wall are mainly caused by chip adhesion and tool wear. The surface-roughness value is the lowest as the cutting speed is 60 m/min and the feed rate is 0.4 mm/rev. The holes machined by the right-hand reamer have a low hole diameter deviation with various cutting parameters. The geometric accuracy of cylindricity is higher as the feed rate is 0.4 mm/rev and the cutting speed is 40 m/min for both kinds of reamers, and the cylindricity is better with the right-hand reamer.

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“…n is the sum of all the selected points. The calculation in Formula (2) is a resultant of the cutting force, as follows [ 20 ].

…”

Section: Resultsmentioning

confidence: 99%

Study on Characteristics for Reaming Titanium Alloy Ti6Al4V with Two Kinds of Cemented-Carbide Groove Reamers

Zhang

Wang

Han³

2022

Materials

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“…High-speed dry cutting is an important processing method that does not make use of cutting fluids [ 1 ]. Ceramic cutting tools are widely used because of their advantages of high-temperature resistance, good wear resistance, high hardness, good chemical stability, low affinity for the processed workpiece material, and considerable resistance to producing chip tumors [ 2 , 3 , 4 ].…”

Section: Introductionmentioning

confidence: 99%

Addition of Nano CaF2@SiO2 and SiC Whiskers in Ceramic Tools for Wear Reduction and Improved Machinability

et al. 2022

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The addition of CaF2@SiO2 and SiC whiskers to ceramic tools can improve their flexural strength and fracture toughness, reduce surface damage, and improve their cutting performance. The cutting experiments showed that under the same cutting conditions, the surface roughness of the workpiece processed with the Al2O3/TiC/SiC/CaF2@SiO2 (ATSC10) tool was significantly lower than that of the workpiece processed with the Al2O3/TiC/ SiC (ATS) tool. Additionally, the main cutting force and cutting temperature when cutting with the ATSC10 tool were lower by 30 and 31.7%, respectively. These results were attributed to the precipitation of CaF2 from the nanocoated particles during cutting and the formation of a uniform and continuous lubricating film on the surface of the tool. The wear on the front surface of the ATS tool was mainly adhesive, and that on the back tool surface was mainly abrasive. For ATSC10, the main forms of wear on the tool front surface were adhesive and abrasive, whereas the main form of wear on the tool back surface was abrasive with slight adhesive wear. The addition of nano-coated particles and whiskers improved the mechanical properties of the cutting tool while maintaining good cutting performance.

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“…High-speed machining (HSM), especially HSD milling, can avoid a series of problems such as high resource consumption, serious pollution emissions and hazards to the occupational health of workers during the cutting process. Therefore, it has received extensive attention within the international community [4].…”

Section: Introductionmentioning

confidence: 99%

Specific cutting energy and surface roughness in high-speed dry milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts

Zhang¹,

Kang²,

Cao³

et al. 2022

Preprint

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Existing research on coated tools does not predict data while exploring the changing rules. As well as the traditional cutting process parameters neither guarantees the surface quality of the 30CrMnSiNi2A nor attains high material removal rate (MRR). Accurate control and prediction of workpiece three-dimensional surface roughness (Sq) and specific cutting energy consumption (SCEC) are of vital significance to improve quality, reduce cost and improve efficiency. Here, according to the new SCEC calculation model and the influence of measuring position on Sq, the SCEC and Sq values are accurately obtained. Then, based on the idea of fitting formula, the influence of cutting parameters on SCEC and Sq in high-speed dry (HSD) milling of 30CrMnSiNi2A steel is analyzed according to CVD and PVD coated inserts. Finally, the SCEC and Sq prediction models considering coating type, cutting speed, feed per tooth and cutting width are established by using the XGBoost algorithm. The R2 values of SCEC and Sq are 0.92465 and 0.91527, respectively, indicating that the model has a good prediction effect on experimental data. The feasibility of HSD milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts is verified by analyzing SCEC, Sq and cutting temperature, which provides experimental basis for high efficiency and high precision machining of 30CrMnSiNi2A steel.

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Cutting responses of additive manufactured Ti6Al4V with solid ceramic tool under dry high-speed milling processes

Cited by 55 publications

References 46 publications

Study on Characteristics for Reaming Titanium Alloy Ti6Al4V with Two Kinds of Cemented-Carbide Groove Reamers

Study on Characteristics for Reaming Titanium Alloy Ti6Al4V with Two Kinds of Cemented-Carbide Groove Reamers

Addition of Nano CaF2@SiO2 and SiC Whiskers in Ceramic Tools for Wear Reduction and Improved Machinability

Specific cutting energy and surface roughness in high-speed dry milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts

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