Investigation of Tool Wear and Chip Morphology in Dry Trochoidal Milling of Titanium Alloy Ti–6Al–4V

Abstract

Titanium alloys are widely used in the manufacture of aircraft and aeroengine components. However, tool wear is a serious concern in milling titanium alloys, which are known as hard-to-cut materials. Trochoidal milling is a promising technology for the high-efficiency machining of hard-to-cut materials. Aiming to realize green machining titanium alloy, this paper investigates the effects of undeformed chip thickness on tool wear and chip morphology in the dry trochoidal milling of titanium alloy Ti–6Al–4V. A tool wear model related to the radial depth of cut based on the volume of material removed (VMR) is established for trochoidal milling, and optimized cutting parameters in terms of cutting speed and axial depth of cut are selected to improve machining efficiency through reduced tool wear. The investigation enables the environmentally clean rough machining of Ti–6Al–4V.

Analysis and Prediction of the Machining Force Depending on the Parameters of Trochoidal Milling of Hardened Steel

“…It also studies chip formation [4] and selected parameters of surface integrity [1,5]. Significant studies have also been carried out in this field, focusing on tool wear, machining not only steel materials but also nickel and titanium alloys [6][7][8].…”

“…The use of the trochoid grooving method places high demands on machine tools that must be able to provide sufficient acceleration to ensure the prescribed workpiece trajectory and have sufficient power to provide the requested speed. Machining force components can be measured indirectly; for example, from the power output of the machine electric motor or the torque of the power relative to the rotation axis [7,30]. In the presented experiments, exact, direct measurements of the components of the total machining force were used using a stationary dynamometer, which measures the rectangular projections of the components of the forces F f , F fn and F p in the 3D coordinate system axes x, y and z.…”

MQL Strategies Applied in Ti-6Al-4V Alloy Milling—Comparative Analysis between Experimental Design and Artificial Neural Networks

“…It has the highest strength-to-weight ratio amongst all structural materials, excellent creep and biocompatibility, a low elastic modulus, and chemical inertness at room temperature [ 11 ]. As a result of these properties, titanium is considered a hard-to-cut material [ 12 ], and the main problems include the fact that the high chemical reactivity makes chips easily adhere to the tool-cutting edge, and the low thermal conductivity (1/6 of that for steel) increases the temperature at the tool’s cutting edge (which can easily reach beyond 1000 °C) [ 13 , 14 , 15 , 16 ]. A low modulus of elasticity and an extreme strength at high temperature generate long ductile chips, a relatively large contact length between the chip and the cutting tool, and a high compressive stress, leading to a poor tool life, or to higher cutting forces [ 17 ].…”

Preparation, Mechanical Properties, and High-Temperature Wear Resistance of Ti–Al–B alloy

“…Titanium alloys are characterized by low density, high strength, and oxidation resistance; they have been widely used as high-temperature mechanical components such as nozzles, divergent flaps and blades in aviation industries, and braking systems [1,2,3,4,5,6]. The mechanical parts could suffer from severe wear at high temperatures.…”