Economic and ecological evaluation of high-pressure cutting fluid supply in milling of Ti-6Al-4V

Lakner, Thomas; Splettstoesser, Antonia; Schraknepper, Daniel; Bergs, Thomas

doi:10.1016/j.procir.2020.11.017

Cited by 5 publications

(3 citation statements)

References 7 publications

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“…The investigation revealed that the application of a high-pressure coolant led to a reduction in cutting temperature (63%), enhancement of surface finish (up to 78%), narrowing of chip width, and an improved cooling effect. Lakner et al [321] analyzed the implementation of a high-pressure coolant in conjunction with a multiple-row shell milling tool. The investigation revealed potential cost savings of up to 20% when employing this technological approach for machining titanium alloys.…”

Section: High-pressure Coolant-assisted Turningmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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Section: High-pressure Coolant-assisted Turningmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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“…Additively manufactured (AM) cutting tools enable new design concepts in tool development including benefits such as lightweight construction [1], damping behavior [2] and internal cutting fluid supply [3]. So far, mainly basic bodies of indexable cutting tools were additively manufactured from steel materials, with conventional cutting inserts mounted.…”

Section: Introductionmentioning

confidence: 99%

Orthogonal cutting with additively manufactured grooving inserts made from HS6-5-3-8 high-speed steel

Kelliger

2023

Materials Research Proceedings

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Abstract. Additive manufacturing (AM) of cutting materials such as high-speed steel (HSS) is very challenging. So far, the impact of the layer-by-layer manufacturing technique onto the AM tool performance during machining is widely unknown. In this study, the performance characteristics of AM grooving inserts manufactured from HS6-5-3-8 (ASP 2030) in AM Laser Powder Bed Fusion (LPBF) process were investigated in fundamental cutting experiments. Six different workpiece materials were analyzed and two different parameter sets for the LPBF process investigated. All AM grooving inserts withstood the thermal and mechanical stresses during machining of the investigated materials. Based on these results, AM threading tools manufactured from HS6-5-3-8 will be investigated in a next step, using the geometrical freedom of the AM process for an adapted channel and outlet nozzle design of the internal cutting fluid supply.

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“…Durch den Einsatz von Kühlschmierstoff (KSS) kann die Prozesssicherheit im Sinne eines fortschreitenden Werkzeugverschleißes sowie der Gewinde-Lehrenhaltigkeit bei der Innengewindefertigung gesteigert werden [2]. Wird die hoch belastete Werkzeug-Werkstück-Kontaktzone durch eine interne KSS-Zufuhr zielgerichtet mit Schmierstoff versorgt, können die Reibung reduziert und die Kühlung verbessert werden [3]. Dies bedingt reduzierte Zerspankräfte und Drehmomente und verlangsamt den Verschleißfortschritt am Gewindewerkzeug.…”

Section: Introductionunclassified

Additiv gefertigte Gewindewerkzeuge aus HSS/Additively manufactured threading tools made from HSS

Kelliger¹,

Meurer²,

Bergs³

2023

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Eine verlängerte Werkzeuglebensdauer bei der Gewindefertigung ist durch eine Neugestaltung der inneren Kühlschmierstoffzufuhr am Werkzeug möglich. Der Einsatz additiver Fertigungsverfahren wie dem Laser Powder Bed Fusion erlaubt die Fertigung innen liegender und komplexer Kanal- und Düsengeometrien. In umfangreichen Einsatztests konnten Prozesssicherheit und Potenziale additiv gefertigter Gewindeform- und Gewindeschneidwerkzeuge aus Schnellarbeitsstahl nachgewiesen werden. Extended tool life in thread production is possible by an adapted internal cutting fluid supply on the tool. The use of additive manufacturing techniques such as Laser Powder Bed Fusion allows the production of internal and complex channel and nozzle geometries. Extensive performance investigations demonstrated the process reliability and great potential of additively manufactured tapping and threading tools made of high-speed steel. The results can now be used for further tool developments.

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Economic and ecological evaluation of high-pressure cutting fluid supply in milling of Ti-6Al-4V

Cited by 5 publications

References 7 publications

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Orthogonal cutting with additively manufactured grooving inserts made from HS6-5-3-8 high-speed steel

Additiv gefertigte Gewindewerkzeuge aus HSS/Additively manufactured threading tools made from HSS

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