Experimental investigation of top burr formation in high-speed micro-milling of Ti6Al4V alloy

Kumar, Mohan; Bajpai, Vivek K.

doi:10.1177/0954405419883049

Cited by 20 publications

(7 citation statements)

References 44 publications

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“…In down milling, the chips formed are thick at the starting point of cutting and thin at the end point. The burr formation [18] is decreased by 50 % as speed varies from conventional to high speed [57], so that the initial heat will be carried away with chips. Another benefit of this type of milling is that the thin portion of chips does not stick to the tool.…”

Section: An Overview Of Machining Of Titanium and Its Alloysmentioning

confidence: 99%

Overview of Machinability of Titanium Alloy (Ti6Al4V) and Selection of Machining Parameters

Gandreddi

Kromanis

Lungevičs

et al. 2023

Latvian Journal of Physics and Technical Sciences

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Machining of titanium alloy Ti6Al4V is a challenging task for the industry; however, there are some solutions to overcome these difficulties. One of those is optimizing the machining parameters. Machining of Ti6Al4V made by additive manufacturing is an emerging future and is even more difficult when comparing to standard Ti6Al4V alloy. There is lot of invention on Ti6AL4V 3D printed samples, but influence of machining post-printing is lacking. In additive manufacturing of Ti6Al4V alloy, it is necessary to make a finishing operation to improve the surface quality and to ensure precise geometry tolerances. During this process, it may affect the workpiece properties such as microhardness, microstructure, internal defect distribution, internal stresses. During printing there are lots of stresses created, heat treatment is done to normalize the parts. Machining (using milling machine) also causes internal stresses which can damage the surface and part itself. Optimisation of machining parameters and printing parameters can solve this issue. This study gives an overview of selection of machining parameters by considering all the previous relevant research.

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Section: An Overview Of Machining Of Titanium and Its Alloysmentioning

confidence: 99%

Overview of Machinability of Titanium Alloy (Ti6Al4V) and Selection of Machining Parameters

Gandreddi

Kromanis

Lungevičs

et al. 2023

Latvian Journal of Physics and Technical Sciences

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“…There is, however, the need to resolve the problem caused by vibration to enable manufacturers to have sustainable production of mechanical components for industrial use [14][15][16][17][18][19][20]. Therefore, this research work is focused on studying the variation of cutting speed and depth of cut on vibration frequency, when order parameters are kept constant.…”

Section: Experimental Analysis Of the Influence Of Depth Of Cut Time Of Cut And Machining Speed On Vibrationmentioning

confidence: 99%

Experimental Analysis of the Influence of Depth of Cut, Time of Cut, and Machining Speed on Vibration Frequency during Turning of AL1060 Alloy

Okokpujie¹,

Ohunakin²,

Bolu³

et al. 2020

IJATCSE

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Machining vibration is a significant concern in the manufacturing industry, as vibration cannot be eliminated during metal to metal turning operations. It can be controlled to the minimum when a proper study is carryout before the turning process. This study aims to experimentally analyse the effect of the individual parameters such as depth of cut (DOC) and cutting speed have on the machining vibration during turning of AL1060 alloy. A computer numerical control (CNC) program was applied to investigate the effects of the different depths of cut such as 1 mm, 1.5 mm, 2 mm, 2.5 mm, and 3 mm. Moreover, cutting speed of 200 m/min, 350 m/min, 500 m/min, and 600 m/min with a constant feed rate of 5 mm/rev have on the machining vibration during the turning process. DTO 32105 frequency analyser an MXC-1600 digital frequency counter was employed to measure the machining vibration for a specific time between 15 seconds to 500 seconds. The result shows that as the depth of cut continually increases, the machining vibration increases and the minimum machining vibration of 131.8 Hz was obtained at cutting speed of 600 m/min, depth of cut of 1 mm, and cutting time of 15 sec. The Pareto chart was further used to analysis the average vibration frequency at the optimised cutting speed of 600 m/min. The surface quality and the cutting tool life can be significantly enhanced with the study of the individual machining parameters.

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“…An overview of different analysis works based on FEM was also made in a review report on burrs and their control. 1 Recently a lot of works was focused [39][40][41] on formation and control of burrs during micro-milling operation. Li et al 40 applied controlled vibration to effectively suppress exit burr formation and to improve surface quality in 6061 aluminum alloy, while another work 39 was concentrated on modelling burr thickness while micro-end milling Ti6Al4V type titanium alloy.…”

Section: Hashimura Et Al Carried Outmentioning

confidence: 99%

“…They could reduce prediction error substantially by including machining temperature in to the model. On the other hand, Kumar and Bajpai 41 worked on the same titanium alloy to observe top burr formed through micro-end milling operation. They reported a decrease in height of top burrs by about 50% while resorting to down milling operation when milling speed was increased to a high speed; up milling, however, showed large increase in burr height.…”

Section: Introductionmentioning

confidence: 99%

An investigation on formation of burrs during milling of aluminium alloy under wet condition

Mandal¹,

Das

Saha

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Undesirable burrs are created out of a machining process. The objective of the present work is to explore the suitable condition to obtain no burr, or negligible burr, around the edge of a machined product at wet condition. Face milling experiments have been carried out on blocks made of aluminum alloy (Alloy-4600M) with a single, coated-carbide inserted cutter for observing the nature of burr formation. Depth of cut has been maintained constant at 3 mm for all sets of experiments. In each experiment set, three cutting velocities (170 m/min, 237 m/min and 339 m/min) and three in-plane exit angles of 30°, 60° and 90° are provided at three different feeds of 0.08 mm/tooth, 0.1 mm/tooth and 0.12 mm/tooth. First set of experiments are done without any exit edge bevel. Similar sets of experiments are carried out with 15° and 30° exit edge bevel angles to find out the condition for minimum burr. The bevel is made of a height of 3 mm. In the present experimental investigation, a minimum burr height of as low as 3 micron is obtained at an in-plane exit angle of 30° and exit edge bevel angle of 15° under the machining condition of 339 m/min cutting velocity and 0.1 mm/tooth feed.

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Experimental investigation of top burr formation in high-speed micro-milling of Ti6Al4V alloy

Cited by 20 publications

References 44 publications

Overview of Machinability of Titanium Alloy (Ti6Al4V) and Selection of Machining Parameters

Overview of Machinability of Titanium Alloy (Ti6Al4V) and Selection of Machining Parameters

Experimental Analysis of the Influence of Depth of Cut, Time of Cut, and Machining Speed on Vibration Frequency during Turning of AL1060 Alloy

An investigation on formation of burrs during milling of aluminium alloy under wet condition

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