Differences in evolution of temperature, plastic deformation and wear in milling tools when up-milling and down-milling Ti6Al4V

Kaltenbrunner, T.; Krückl, H.P.; Schnalzger, Georg; Klünsner, Thomas; Teppernegg, Tamara; Czettl, Christoph; Ecker, Werner

doi:10.1016/j.jmapro.2022.03.010

Cited by 17 publications

(6 citation statements)

References 31 publications

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“…The linear equation used to predict the tool wear for turning with water soluble coolant and nanofluid can be expressed as [35]:…”

Section: Development Of Linear Tool Life Model With Mwf and Mxene-nfcmentioning

confidence: 99%

Enhancing Machining performance in Stainless Steel Machining using MXene Coolant: A Detailed Examination

Eaki,

Kadirgama,

Ramasamy

et al. 2024

Int. J. Automot. Mech. Eng.

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Metal cutting, a complex process in manufacturing, involves various factors that significantly affect the quality of the final product. Notably, the turning process is crucial, with outcomes that heavily depend on multiple machining parameters. These parameters encompass speed, depth of cut, feed rate, the type of coolant used (specifically, high heat transfer MXene coolant), and insert types, among others. The material of the workpiece is also a critical factor in the metal-cutting operation. This study focuses on achieving optimal surface quality and minimizing cutting forces in the turning process. It recognizes the substantial impact of numerous process parameters, directly or indirectly affecting the product's surface roughness and cutting forces. Understanding these optimal parameters can lower machining costs and improve product quality. Our research concentrates on turning a stainless-steel alloy workpiece using a carbide insert tool. We employ the Response Surface Method (RSM) to optimize cutting parameters within a set range of cutting speed (100, 125, 150 m/min), feed rate (0.1, 0.2, 0.3 mm/rev), and depth of cut (0.4, 0.8, 1.2 mm). Additionally, we use various tool geometries and the RSM design of experiments to enhance and analyze the multi-response parameters of surface roughness and tool life. Optimal machining parameters for MXene-NFC involve a cutting speed of 140 m/min, a feed rate of 0.05 mm/rev, and a depth of cut of 0.5 mm. These settings ensure minimal surface roughness, maximum tool life, and the greatest total length of cut, achieving a composite desirability of 0.695.

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“…The linear equation used to predict the tool wear for turning with water soluble coolant and nanofluid can be expressed as [35]:…”

Section: Development Of Linear Tool Life Model With Mwf and Mxene-nfcmentioning

confidence: 99%

Enhancing Machining performance in Stainless Steel Machining using MXene Coolant: A Detailed Examination

Eaki,

Kadirgama,

Ramasamy

et al. 2024

Int. J. Automot. Mech. Eng.

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“…To reduce the thermal load and consequently the thermo-chemical induced tool wear when cutting Ti-6Al-4V, a very low cutting speed is generally chosen [17] This however results in low productivity which is why machining Ti-6Al-4V is often associated with high manufacturing costs [18]. In addition, up milling has to be generally avoided, since the process kinematic promotes higher thermo-mechanical loads in comparison to down milling due to ploughing effects [19]. Other attempts to improve the machinability of the titanium alloy rely on the use of coatings [20] or cutting edge preparation [21,22].…”

Section: Introductionmentioning

confidence: 99%

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Gutzeit

Bulun²,

Stelzer³

et al. 2023

Preprint

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Due to an excellent ratio of high strength and low density, Ti-6Al-4V is suitable for many industrial applications, especially in the aerospace industry. However, Ti-6Al-4V is also characterized as a hard to-cut material. This is mainly attributed to its very low thermal conductivity and high chemical reactivity, especially at elevated temperatures. Machining Ti-6Al-4V leads to high cutting temperatures and thermal loads of the tools within the cutting zone. This enhances a rapidly progressing, thermo-chemical induced tool wear reducing tool life and productivity. To enhance the cutting performance, suitable cooling strategies are a necessity to reduce the thermal load and hence to improve the machinability of Ti-6Al-4V. A novel, highly efficient cooling approach is to apply sub-zero metalworking fluids (MWF) at liquid state but at supply temperatures well below 0°C. These sub-zero MWF inhibit high cooling effects due to their low supply temperature in superposition with a beneficial wetting behavior. Within this paper, the application of a sub-zero cooling strategy is investigated and compared to a cryogenic CO2 cooling. The performance of both cooling strategies is analyzed when milling Ti-6Al-4V by systematically varying the cutting parameters and the milling strategy. The milling process is described on the basis of the occurring forces, the resulting wear and the surface quality. The results show that the sub-zero cooling outperforms the cryogenic CO2 cooling, especially at elevated cutting parameters and unfavorable cutting conditions. Less tool wear and an overall better surface quality are observed for sub-zero milling when being compared to cryogenic milling.

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“…This material is known to be difficult to machine, and the microstructure will change dramatically when it encounters high pressure and high temperature during cutting. The law and properties of Ti6Al4V microstructure in the environment of high temperature and high pressure become a research focus of cutting mechanism [2]. Dynamic recrystallization is a microstructure change that may occur in the cutting process, which is easy to cause material softening to some extent [3].…”

Section: Introductionmentioning

confidence: 99%

Experimental study on dynamic recrystallization of titanium alloy Ti6Al4V at different strain rates

Liu

Zhang

Zhao

et al. 2022

Mater. Res. Express

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The dynamic recrystallization condition and law of Ti6Al4V. alloy at all strain rates are investigated through thermal processing simulation test, split Hopkinson compression bar test and milling test. The theoretical calculation of the experimental results and the microstructure observation show that the dynamic recrystallization is possiblethe under the conditions of high strain rate and low strain rate. The model uses two expressions to express the material constitutive characteristics of different critical strain value intervals; the subprogram written in Fortran language is imported into AdvantEdge FEM software, and the finite element analysis of John-Cook constitutive and improved constitutive is carried out respectively. The comparative study of simulation proves that the improved constitutive equation is closer to the high temperature and high impact environment of high-speed cutting of titanium alloy, which has certain guiding significance for high-speed cutting of titanium alloy.

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Differences in evolution of temperature, plastic deformation and wear in milling tools when up-milling and down-milling Ti6Al4V

Cited by 17 publications

References 31 publications

Enhancing Machining performance in Stainless Steel Machining using MXene Coolant: A Detailed Examination

Enhancing Machining performance in Stainless Steel Machining using MXene Coolant: A Detailed Examination

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Experimental study on dynamic recrystallization of titanium alloy Ti6Al4V at different strain rates

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