Experimental study of coated carbide tools behaviour: application for Ti-5-5-5-3 turning

Abstract

OATAO is an open access repository that collects the work of Toulouse researchers and makes it freely available over the web where possible. Abstract: The goal of this paper is to study the relation between the input data (conditions and geometry of cut) and answers (wear of tool, forces and cutting temperatures) when machining the Ti-5-5-5-3 alloy treated. This study has shown that the cutting process is different and that the slip forces are preponderates. Compared with other materials, the specific cutting pressure is higher and does not vary according to the cutting speed but depend on feed rate. Moreover, both edge preparation and feed rate have an influence on cutting force direction. Besides, cutting temperatures are high and almost similar to those provided by high speed machining with low cutting speed. Finally, we have shown that failure modes are different from those obtained when machining other titanium alloys. Built-up edge is the most deteriorating phenomenon and no flank wear was met in our study context. Keywords:Ti-5-5-5-3; cutting force; cutting temperature; cutting conditions; tool geometry; wear.Reference to this paper should be made as follows: Wagner, V., Baili, M., Dessein, G. and Lallement, D. (2011) 'Experimental study of coated carbide tools behaviour: application for Ti-5-5-5-3 turning', Int. J. Machining and Machinability of Materials, Vol. 9, Nos. 3/4, pp.233-248.Biographical notes: Vincent Wagner is an Associate Professor which is presently preparing his PhD work at the Laboratory Genus of Production, France. His researches are focused on cutting force model and cutting temperature. He works also on increasing of titanium alloys machinability.Maher Baili is an Assistant Professor of Mechanical Design and Production in the National Tarbes Engineering School. His research topics are machining of hard-to-cut materials, cutting forces modelling and surface integrity.Gilles Dessein is an Assistant Professor of Production in the National Tarbes Engineering School. His research topics are high performance machining and CAD-CAM. His current research focuses on stability and dynamics of milling process, solution against thin walled part vibrations, surface integrity and machining of hard-to-cut materials.Daniel Lallement works as an Engineer in the Department of Manufacturing Engineering at the Bidos Center, Messier Dowty. His actual topic is the analyses of Ti-5-5-5-3 cutting specificities, in order to develop better tools and improve a global process that will ensure optimised productivity gains.

Study of Ti-1023 milling with toroidal tool

“…However, during the machining of Ti-1023, this evolution does not appear. Wagner and coworkers show also a low influence of cutting speed on specific cutting energy during the Ti-5553 machining [10]. These phenomena are explained by the high mechanical properties of titanium alloys in high temperatures combined with the low thermal properties of titanium alloys.…”

“…It's defined as the cutting speed where the specific energy remains minimum and with a minimum variation. For Ti-1023 machining and as for other titanium alloy [10], it's very difficult to define this limit. Concerning the tool 1, the V cmin appears when V c = 35 m/min and for tool 2 the V cmin can be defined at 30 m/min.…”

“…The first can be assimilated to a crater wear, which occurs like a concave section on the rake face generated by the chip sliding. The titanium machining is an abrasive process [10]. The contact between chip and tool on the rake face combined with high temperatures generates tearing of some coating particles.…”

“…Accordingly, the cutting temperature at the tool chip-interface increases. With a thermocouple placed inside the tool close to the cutting edge, Wagner and coworkers observe the tool temperature [10]. They note an increase of the cutting temperatures with highest cutting speeds.…”

The relationship between the cutting speed, tool wear, and chip formation during Ti-5553 dry cutting

“…The choice of cutting forces compared to cutting temperatures has been validated through another tests ( [8]). In order to measure cutting temperatures, the Actarus's system has been used.…”