Influence of cutting speed and tool wear on the surface integrity of the titanium alloy Ti-1023 during milling

Abstract

This study focuses on the machined surface integrity of the titanium alloy Ti-10V-2Fe-3Al (Ti-1023) during face milling. Surface roughness, machining defect, microhardness, and microstructure variations are investigated at different cutting speeds and tool average flank wear (VB) values. Experimental results show that surface roughness increases when cutting speed is increased from 40 to 100 m min −1 and decreases when cutting speed is increased from 100 to 300 m min −1 by using a new tool. Moreover, surface roughness values are stable when cutting speed is increased by using a worn tool at VB =0.2 mm and increases when VB is increased. As for defects, the machining defect is determined to be dependent on cutting speed and tool wear directions. Microhardness is decreased to 35 μm beneath the machined surface at different cutting speeds by using a new tool. The influence of tool wear on hardening is significant, with the depth of hardening being less than 55 μm by using a worn tool at VB=0.2 mm and reaching 130 μm at VB=0.35 mm. No significant phase transformation or evident deformation can be observed at different cutting speeds by using a new tool (initial wear). Severe plastic deformation and deep alteration of the microstructure in the machined surface are produced with VB from initial wear to VB=0.35 mm. VB is best maintained at less than 0.2 mm for finish machining of Ti-1023.

Machining of biocompatible materials — Recent advances

“…The microhardness at the machined surface can significantly (e.g. 70-90%) increase when compared with that of the bulk material [54,77]. This aspect is of high relevance when considering the contact conditions between the different components of the implants as well as with the host organs (Fig.…”

Artificial intelligence for automatic prediction of required surface roughness by monitoring wear on face mill teeth

“…Much of the research devoted to the study of surface roughness in face milling (Diniz and Filho 1999;Caldeirani Filho and Diniz 2002;De Souza et al 2003, 2005De Escalona and Maropoulos 2010;Prasad et al 2011;Houchuan et al 2015;Liu et al 2016;Shi et al 2016;Werda et al 2017) takes tool wear into account. Diniz and Filho (1999) studied the influence of the relative positions of tool and workpiece on tool life, tool wear, and surface finish in the face milling process, taking tool wear into account.…”

“…Prasad et al (2011) studied the impact of offsets due to vibration during face milling and the correlation of surface roughness with tool wear under different cutting conditions while monitoring the tool state. Houchuan et al (2015) investigated surface roughness, machining defects, microhardness, and microstructure variations at different cutting speeds and tool average flank wear values in the face milling of a titanium alloy, Ti-10V-2Fe-3Al (Ti-1023). Liu et al (2016) investigated the process of tool damage and its effect on machined surface roughness in high-speed face milling of 17-4PH stainless steel.…”

“…Werda et al (2017) compared tool life and surface roughness in the milling of X100CrMoV5 mold steel under different lubrication conditions: dry machining and minimum quantity lubrication (MQL). Even though many authors (Diniz and Filho 1999;Caldeirani Filho and Diniz 2002;De Souza et al 2003, 2005De Escalona and Maropoulos 2010;Prasad et al 2011;Houchuan et al 2015;Liu et al 2016;Shi et al 2016;Werda et al 2017) have presented the results of surface roughness studies that take into account tool wear, no solutions to the problem of how to establish a comprehensive correlation of surface roughness, tool wear, and processing time have been advanced from the perspective of managing these settings in automated production. This task is however made possible with AI.…”

Influence of Wear and Tool Geometry on the Chatter, Cutting Force, and Surface Integrity of TB6 Titanium Alloy with Solid Carbide Cutters of Different Geometry

“…This behaviour was caused by different wear states of tool flank face. However, Yang et al [27] reported contradictory results, in which the machined surface roughness of TB6 presented an increasing trend with the increase of tool flank wear. Tool wear also had significant influence on residual stress and microhardness.…”