Evaluation of a Novel Controlled Cutting Fluid Impinging Supply System When Machining Titanium Alloys

Abstract

Abstract:Following a comprehensive review on titanium machining and methods of cutting fluid application, this paper presents a new Controlled cutting fluid impinging supply system (Cut-list) developed to deliver an accurate amount of cutting fluid into the machining zone via well-positioned coherent nozzles based on the calculation of the heat generated. The performance of the new system was evaluated against a conventional flood cutting fluid supply system during step shoulder milling of Ti-6Al-4V using vegetable oil-based cutting fluid. The comparison was performed at different cutting speeds and feed rates. Comparison measures/indicators were cutting force, workpiece temperature, tool flank wear, burr formation and average surface roughness (Ra). The new system provided significant reductions in cutting fluid consumption of up to 42%. Additionally, reductions in cutting force, tool flank wear and burr height of 16.41%, 46.77%, and 31.70% were recorded, respectively. Smaller Ra values were also found with the use of the new system.

Experimental analysis of system parameters for minimum cutting fluid consumption when machining Ti-6Al-4V using a novel supply system

“…It significantly reduced cutting fluid consumption up to 42%, cutting force by 16.41%, tool flank wear by 46.77% and burr formation by 31.70%. However, no notable discrepancy in workpiece temperature values was found between the two systems [67]. Feed rate was the dominant factor affecting mean cutting force, burr formation and surface roughness, whilst cutting speed has the greatest impact on workpiece temperature and tool flank wear.…”

Analysis of Microstructure and Chip Formation When Machining Ti-6Al-4V

“…In previous work by the present authors [2], their new Cut-list system showed superior machining performance compared to conventional systems, particularly in terms of reductions in cutting fluid consumption (42%), cutting force (16%), tool flank wear (46.77%), and burr formation (31.70%).…”

“…Cutting fluids also contribute to reducing the contact pressure between the cutting tool and workpiece material and dissipate heat from the machining zone, resulting in extended tool life and reduced power consumption [1]. More details of the benefits, types of cutting fluid, their environmental impacts and supply systems, problems and requirements when machining titanium alloys, as well as the detailed design and fabrication of the new cutting fluid supply system known as Cut-List developed by the authors are available in previous publications [2,3]. This paper presents results related to microstructure and chip formation which have not yet been reported.…”

“…These unique features enhance the penetrability of Cut-list during the cutting process. More details of the design procedure of the new supply system can be found elsewhere [2]. considered as one of the crucial indicators that can be used to estimate the amount of plastic deformation in the produced chip [29].…”

Poly(methyl methacrylate) Coating of Titanium Workpieces to Reduce Burrs in Micro-drilling

“…Referring to the process parameter, a linear correlation between the burr height and feed per tooth was found [7], in particular, benefits have been achieved imposing a feed variation model based on a sinusoidal function [8]. Gariani et al reduced burr height controlling the cutting fluid quantity as a function of the heat generated [9]. Drill bit geometry still influences the burr generated and a direct correlation between burr height and cutting edge radius still exists [10].…”