Investigation of the Machining Behavior of Ti6Al4V/TiC Composites During Conventional and Laser-Assisted Machining

Abstract

Conventional machining of Ti6Al4V/TiC composites is a very difficult process, which exhibits a peculiar cutting force pattern where the thrust forces are higher than the tangential forces. This behavior results in rapid tool wear and consequently very short tool life. This study is concerned with describing the reasons for the attendant behavior using experimentally validated 3D finite element simulations and alleviating this behavior via laser assisted machining (LAM). Simulations were conducted using an equivalent homogeneous model (EHM) and a multiscale heterogeneous model (MHM) of the Ti6Al4V/TiC composite. Results showed a good agreement between the tangential forces obtained from experiments, EHM, and MHM for conventional machining and LAM. However, only the MHM was able to successfully predict the unusual high thrust forces. The MHM simulation results showed that the tool/particle interaction along the tool nose region presented the highest resistance due to the high resistance against pushing the TiC particles by the tool into the machined surface. This resistance results from the efficient load transfer capability between the particles and the matrix below the machined surface. When using LAM, the stated resistance was decreased by the reduction in load transfer capability of the Ti6Al4V/TiC workpiece such that the thrust and tangential forces were reduced by 78% and 37%, respectively, according to the MHM simulation. The experimental results showed that the tool wear was improved by 68% by LAM. All the results demonstrated that the MHM successfully captured the underlying machining mechanism of the Ti6Al4V/TiC composites.

Determination of Optimum Machining Parameters for Face Milling Process of Ti6A14V Metal Matrix Composite

“…Taguchi L9 Orthogonal Array is used for Design of Experiment because it provides fewer runs for the experiment [ 26 , 27 , 28 , 29 , 30 ]. Cutting velocity (V), feed (F) and depth of cut (D) are taken as the input machining parameters.…”

Micromilling of Ti6Al4V alloy assisted by plasma electrolytic oxidation

“…It reduced the normal and tangential forces by 78% and 37%, respectively. Moreover, the method decreased tool wear by 68% due to the reduced load transfer capacity of the workpiece [25]. Baek et al investigated the cutting force and energy efficiency of the laser-assisted cycloid milling (LAM) used to process Ti-6Al-4V cycloid under different conditions.…”

Ti–6al–4v Sicak İşlenmesi̇ Üzeri̇ne Etki̇leri̇ni̇n Sonlu Elemanlar Yöntemi̇ İle İncelenmesi̇

“…Ti6Al4V/TiC kompozitlerin kesimine lazer ısıtmayı dahil etmişlerdir. İş parçasının azaltılmış yük transfer kapasitesi nedeniyle, normal ve teğetsel kuvvetler sırasıyla %78 ve %37 oranında azaltılmasının yanında takım aşınmasının da %68 oranında azaltıldığı görülmüştür (Elkhateeb & Shin, 2019). Diğer bir çalışmada, minimum miktarda yağlama ile Ti6Al4V alaşımının lazer destekli işlenmesinde, geleneksel işlemeye göre takım aşınmasının %49,1 yüzey pürüzlülüğünün ise %33,7 azaldığı kaydedilmiştir (Luan et al, 2021).…”