Cutting tool wear minimization in drilling operations of titanium alloy Ti-6Al-4V

Soori, Mohsen; Arezoo, Behrooz

doi:10.1177/13506501231158259

Cited by 13 publications

(4 citation statements)

References 42 publications

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“…The built-up edge is also one of the problems associated with dry drilling that ultimately affects the tool and thus problems associated with dry drilling that ultimately affects the tool and thus redu hole quality; however, drilling in dry conditions is environmentally friendly as it r the environmental effect of coolants [8,9]. Hence, to achieve a long tool life and h mensional accuracy, drilling performance is therefore dependent on a variety of va including tool geometry, tool materials, drilling parameters such as the spindle sp and feed rate (f), the type of drilling machine, and the absence or presence of co [10,11]. Therefore, researchers are interested in optimizing/investigating these imp drilling parameters to maximize productivity.…”

Section: Introductionmentioning

confidence: 99%

Experimental Assessment of Hole Quality and Tool Condition in the Machining of an Aerospace Alloy

et al. 2023

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This paper deals with an experimental investigation of hole quality in Al2024-T3, which is one of the aerospace alloys used in aircraft fuselage skin due to its high level of resistance to fatigue crack propagation. The experiments are conducted with 6 mm uncoated carbide and HSS drill bits using a CNC machine under dry conditions and different drilling parameters. The characteristics of the hole quality are investigated in terms of its perpendicularity, cylindricity, circularity and hole size. An ANOVA (analysis of variance) and Pareto charts are used to analyze the effects of the drilling parameters on the hole quality. The hole quality is also assessed using a digital microscope to observe the formation of hole burrs. Moreover, scanning electron microscopy is also used to investigate the inside-hole surface defects. Further investigations are carried out using optical microscopy to inspect the post-drilling tool condition at high drilling parameters. The results show that hole quality reduces as the feed rate and spindle speed increase. However, from the ANOVA results and Pareto charts, the influence of the feed rate on the hole quality is found to be insignificant. At the same time, the type of drill bit material shows the highest percentage of contribution affecting the hole quality, following the spindle speed. The HSS drill bit shows more adhesion and built-up edges than the uncoated carbide drill bit. There were more burrs formed at the hole edges when the holes were drilled with uncoated HSS drill bits. In the same way, the SEM analysis reveals more surface deformation and damage defects inside the hole walls of holes drilled using the uncoated HSS drill bit.

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Section: Introductionmentioning

confidence: 99%

Experimental Assessment of Hole Quality and Tool Condition in the Machining of an Aerospace Alloy

et al. 2023

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“…Soori and Arezoo described optimal machining settings utilising the Taguchi optimisation technique to reduce surface integrity and residual stress during grinding operations of Inconel 718 (Soori and Arezoo 2022a). To analyse and minimise cutting tool wear during drilling operations of Titanium alloy Ti6Al4V, optimised drilling parameters is obtained by Soori and Arezoo (Soori and Arezoo 2023).…”

Section: Introductionmentioning

confidence: 99%

Dimensional, geometrical, thermal and tool deflection errors compensation in 5-Axis CNC milling operations

Soori

Arezoo

2023

Australian Journal of Mechanical Engineering

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The dimensional, geometrical, thermal and tool deflection errors which have a big portion of the overall error of machined parts need more attention in precision of components produced by using CNC machine tools. As a result, it is essential to simulate and compensate the errors in the machined components in order to increase accuracy of machined parts. In order to simulate and analyse the real manufactured components in virtual environments, virtual machining systems are proposed. In this paper, application of virtual machining system is investigated in order to simulate and compensate dimensional, geometrical, thermal and tool deflection errors in 5-axis milling operations of free form surfaces. The volumetric error vectors regarding the dimensional, geometrical, thermal and tool deflection errors at each cutting tool location throughout the machining pathways are calculated and compensated utilising the study's created virtual machining technology. In order to validate the study, a sample workpiece free from surfaces is milled by using the 5-axis CNC machine tool. The machine part is then measured by suing the CMM machine in order to obtain the dimensional, geometrical, thermal and tool deflection errors during milling operations of free form surfaces. Thermal sensors are also installed to the different locations of CNC machine tool in order to measure the thermal error of CNC machine tool during machining operations. Finally, in order to improve accuracy in 5-axis milling operations of free form surfaces, new cutting tool paths regarding the compensated volumetric errors of dimensional, geometrical, thermal, and tool deflection errors are generated. As a result, by utilising the proposed virtual machining system in the research work, precision as well as reliability during 5-axis milling operations of free form surfaces can be enhanced.

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“…The continuous chips formed during drilling scratched the hole surface and deteriorated the surface finish. Soori and Arezoo [19] analyzed the tool wear while drilling Ti6Al4V. A virtual model to predict and minimize the wear was also developed.…”

Section: Introductionmentioning

confidence: 99%

Machining Temperature, Surface Integrity and Burr Size Investigation during Coolant-Free Hole Milling in Ti6Al4V Titanium Alloy

et al. 2023

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Modern Aircraft structures use titanium alloys where the processing of holes becomes essential to assemble aerospace parts. Considering the limitations of drilling, the study evaluates the helical milling for hole processing in Ti6Al4V. The experimental evaluation was conducted by considering burr size, surface roughness, machining temperature, and microhardness under coolant-free conditions. The axial feed and cutting speed were varied at three levels, and nine experiments were conducted. The results exhibit a lower machining temperature during helical milling than during drilling. In addition, the helical milling helped to lower the surface roughness and size of the exit burrs. However, helical-milled holes showed higher subsurface microhardness than conventionally drilled holes. The process variables were influential on machining temperature magnitude. The highest recorded temperature of 234.7 °C was observed at 60 m/min of cutting speed and 0.6 mm/rev feed. However, the temperature rise did not affect the microhardness. Strain hardening associated with mechanical deformation was the primary mechanism driving the increase in microhardness. Helical-milled holes exhibited an excellent surface finish at lower axial feeds, while chatter due to tool deformation at higher feeds (0.6 mm/rev) diminished the surface finish. The surface roughness increased by 98% when the cutting speed increased to 60 m/min from 20 m/min, while a moderate increment of 28% was observed when the axial feed increased to 0.6 mm/rev from 0.2 mm/rev. Furthermore, the formation of relatively smaller burrs was noted due to significantly lower thrust load and temperature produced during helical milling.

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Cutting tool wear minimization in drilling operations of titanium alloy Ti-6Al-4V

Cited by 13 publications

References 42 publications

Experimental Assessment of Hole Quality and Tool Condition in the Machining of an Aerospace Alloy

Experimental Assessment of Hole Quality and Tool Condition in the Machining of an Aerospace Alloy

Dimensional, geometrical, thermal and tool deflection errors compensation in 5-Axis CNC milling operations

Machining Temperature, Surface Integrity and Burr Size Investigation during Coolant-Free Hole Milling in Ti6Al4V Titanium Alloy

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