Experimental study on micro-milling of Ti6Al4V with minimum quantity lubrication

Zheng, Xin; Liu, Zhiqiang; Chen, Ming; Wang, Xibin

doi:10.1504/ijnm.2013.057600

Cited by 17 publications

(15 citation statements)

References 20 publications

(20 reference statements)

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“…Zheng et al 48 reported a significant improvement in the machinability of Ti-6Al-4V while micro-milling under MQL conditions. The use of environment-friendly lubricant at a flow rate of 10 mL/h and at the air pressure of 0.4 MPa resulted in higher tool life, that is, tool wear comparatively 50% lesser than that of dry condition, and better surface finish.…”

Section: Previous Work On Sustainable Machining Of Titanium Alloysmentioning

confidence: 99%

Sustainable machining of titanium alloys: A critical review

Gupta

Laubscher

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

173

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The three main pillars of sustainability are the society, the environment, and the economy (people, planet, and profit). The key drivers that sustain these three pillars are energy and resource efficiency, a clean and ‘green’ environment that incorporates effective waste reduction and management, and finally cost-effective production. Sustainable manufacturing implies technologies and/or techniques that target these key drivers during product manufacture. Because of the effort and costs involved in the machining of titanium and its alloys, there is significant scope for improved sustainable manufacturing of these materials. Titanium and its alloys are extensively used for specialized applications in aerospace, medical, and general industry because of their superior strength-to-weight ratio and corrosion resistance. They are, however, generally regarded as difficult-to-machine materials. This article presents an overview of previous and current work and trends as regards to sustainable machining of titanium and its alloys. This article focuses on reviewing previous work to improve the sustainable machining of titanium and its alloys with specific reference to the selection of optimum machining conditions, effect of tool materials and geometry, implementing advanced lubrication and/or cooling techniques, and employing advanced and hybrid machining strategies. The main motivation is to present an overview of the current state of the art to discuss the challenges and to suggest economic and environment-friendly ways for improving the machinability of titanium and its alloys.

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Section: Previous Work On Sustainable Machining Of Titanium Alloysmentioning

confidence: 99%

Sustainable machining of titanium alloys: A critical review

Gupta

Laubscher

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

173

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“…In addition, the quality and quantity of drilled holes was superior to those obtained when pure MQL and compressed air was used. Zheng et al [41] also indicate an improvement in tool life (Fig. 7) and reduced material adhesion while micro-milling Ti-6Al-4V in contrast with dry cutting.…”

Section: Minimum Quantity Lubricationmentioning

confidence: 90%

“…Often, the amount of coolant (below 10 ml/min) is nearly 3 to 10 orders of magnitude lower than conventional flood cooling [39,41]. Other advantages include reduced cost and tool wear, improved surface quality, a reduction in environmental and worker health hazards and nearly clean chips.…”

Section: Minimum Quantity Lubricationmentioning

confidence: 99%

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

Giraldo¹,

Serje²,

Bolívar³

et al. 2017

DYNA

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Micro-machining of different polymer based components often require high precision and excellent surface quality at high production rates with low costs. Micro-milling is a cost-efficient micro-machining process capable of generating complex shapes in a wide range of materials. Challenges based on size effect, burr formation and adequate chip removal must be faced and are addressed in this research. Material removal mechanisms, as well as its impact on burr formation and control are reviewed, followed by a case study through the application of gaseous cooling based on vortex tubes. Different vortex generator configurations were tested, proving to be fast response an economically-friendly alternative for burr reduction while micro-milling biopolymers. Configurations, as mentioned above, were used for biopolymer micro-milling towards burr measurement after each test; achieving as a result, a burr reduction while cooling temperature decreases.Keywords: Micro-milling; Burr; Polymer machining; Vortex cooling.Formación de rebabas y su control para el micro-fresado de polímeros: Un caso de estudio con refrigeración por tubo vortex Resumen El micro-maquinado de diferentes componentes basados en polímeros a menudo requiere de gran precisión y un excelente acabado superficial a unas tasas elevadas de producción con un bajo costo. El micro-fresado es un proceso costo-efectivo de micro-maquinado capaz de generar formas complejas en una amplia variedad de materiales. Retos basados en el efecto tamaño, formación de rebabas y una adecuada remoción de la viruta deben ser enfrentados y son tratados en la presente investigación. Los mecanismos de remoción de material, al igual que su impacto en la formación de rebabas y su control, son revisados, acompañados de un caso de estudio a través de la aplicación de refrigeración gaseosa basada en tubos vortex. Diferentes configuraciones de generadores de vortex son probados, demostrando ser una alternativa de respuesta rápida, económica y amigable para la reducción de rebabas mientras se micro-fresan biopolímeros. Dichas configuraciones se utilizaron en el micro-mecanizado de un polímero bio-compatible, midiendo el tamaño de rebaba que se genera en cada prueba, dando como resultado la disminución de estas a media que baja la temperatura de refrigeración.Palabras clave: Micro-fresado; Rebaba; Maquinado de polímeros; Refrigeración con tubo vortex.

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“…The specific cutting force (SCF) is the amount of required force that is applied to unit cutting area. 22 In particular, since the uncut chip thickness in the micro-milling process and the cutting edge radius are of comparable size, the change of the SCF is used to determine the minimum chip thickness. When the uncut chip thickness is smaller than the cutting edge radius (i.e.…”

Section: Methodsmentioning

confidence: 99%

An experimental analysis of minimum chip thickness in micro-milling of two different titanium alloys

Aslantaş

Alatrushi

Bedir

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Micro-milling is a micro-mechanical cutting method used to obtain complex and three-dimensional micro geometries. Micro-cutting tools are used in the manufacturing of micro-components and the type of workpiece is also important for good surface quality and minimum burr. In this study, micro machinability of Ti6Al4V alloy which is used most frequently in micro-component production is compared with Ti5553 alloy. Micro-milling of Ti5553 alloy and comparison of the minimum chip thickness with Ti6Al4V were performed for the first time in this study. Using different cutting parameters, the variation of surface roughness, burr width, and cutting forces were investigated. The cutting tests were carried out on a specially designed and high-precision micro-milling test system using a TiCN-coated two-flute end mill of 0.6 mm diameter. According to the results, minimum chip thickness is approximately 0.3 times the edge radius of the cutting tool and does not vary with the alloy type. At feed rates smaller than the minimum chip thickness, both the cutting forces increase and the surface quality decreases. For both alloys, reduced feed rate and increased depth of cut lead to increased burr width. The burr widths in Ti6Al4V alloy are higher. At the end of the study, the limits of the cutting parameters where plowing occurred for the both alloys are clearly determined. In addition, the limits of the cutting parameter causing plowing have been confirmed by cutting forces, surface roughness, and burr formation.

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Experimental study on micro-milling of Ti6Al4V with minimum quantity lubrication

Cited by 17 publications

References 20 publications

Sustainable machining of titanium alloys: A critical review

Sustainable machining of titanium alloys: A critical review

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

An experimental analysis of minimum chip thickness in micro-milling of two different titanium alloys

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