Optimisation and tool life study in drilling of titanium (Ti-6Al-4V) alloy

Prabukarthi, A.; Krishnaraj, V.; Santhosh, M.; Senthilkumar, M.; Zitoune, Rédouane

doi:10.1504/ijmmm.2013.053219

Cited by 9 publications

(5 citation statements)

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“…Electrical Discharge Machining (EDM) has proven itself a capable method for machining a variety of materials [4,8] and was successfully applied in machining titanium [9,10,11,12,13], metal matrix composites [14,15,16,17] as well as ceramic composites [4,18,19,20,21]. The ability of EDM to remove material without application of mechanical force has the possibility of eliminating many of the difficulties seen in conventional machining of composite materials such as drilling.…”

Section: Introductionmentioning

confidence: 99%

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining

Spaulding

2016

Materials

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An experimental investigation was conducted to determine the application of die sinker electrical discharge machining (EDM) as it applies to a hybrid titanium thermoplastic composite laminate material. Holes were drilled using a die sinker EDM. The effects of peak current, pulse time, and percent on-time on machinability of hybrid titanium composite material were evaluated in terms of material removal rate (MRR), tool wear rate, and cut quality. Experimental models relating each process response to the input parameters were developed and optimum operating conditions with a short cutting time, achieving the highest workpiece MRR, with very little tool wear were determined to occur at a peak current value of 8.60 A, a percent on-time of 36.12%, and a pulse time of 258 microseconds. After observing data acquired from experimentation, it was determined that while use of EDM is possible, for desirable quality it is not fast enough for industrial application.

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Section: Introductionmentioning

confidence: 99%

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining

Spaulding

2016

Materials

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“…Moreover, the development of the fuzzy model helped to predict the two responses quicker. Prabukarthi et al [12] analyzed the behaviour of spindle speed and feed on surface roughness, burr size, hole geometrical quality, and cutting forces during dry drilling Ti6Al4V. Feed rate significantly impacted the burr size, hole size, and cutting forces, with lower feed levels helping to reduce the burr size, cutting forces, and diametrical deviation.…”

Section: Introductionmentioning

confidence: 99%

Machining Temperature, Surface Integrity and Burr Size Investigation during Coolant-Free Hole Milling in Ti6Al4V Titanium Alloy

et al. 2023

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Modern Aircraft structures use titanium alloys where the processing of holes becomes essential to assemble aerospace parts. Considering the limitations of drilling, the study evaluates the helical milling for hole processing in Ti6Al4V. The experimental evaluation was conducted by considering burr size, surface roughness, machining temperature, and microhardness under coolant-free conditions. The axial feed and cutting speed were varied at three levels, and nine experiments were conducted. The results exhibit a lower machining temperature during helical milling than during drilling. In addition, the helical milling helped to lower the surface roughness and size of the exit burrs. However, helical-milled holes showed higher subsurface microhardness than conventionally drilled holes. The process variables were influential on machining temperature magnitude. The highest recorded temperature of 234.7 °C was observed at 60 m/min of cutting speed and 0.6 mm/rev feed. However, the temperature rise did not affect the microhardness. Strain hardening associated with mechanical deformation was the primary mechanism driving the increase in microhardness. Helical-milled holes exhibited an excellent surface finish at lower axial feeds, while chatter due to tool deformation at higher feeds (0.6 mm/rev) diminished the surface finish. The surface roughness increased by 98% when the cutting speed increased to 60 m/min from 20 m/min, while a moderate increment of 28% was observed when the axial feed increased to 0.6 mm/rev from 0.2 mm/rev. Furthermore, the formation of relatively smaller burrs was noted due to significantly lower thrust load and temperature produced during helical milling.

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“…The reason lies in the different properties and machining characteristics of the CFRP and titanium alloy. For instance, the anisotropic architecture and high abrasiveness of the fibrous composites often lead to severe hole damage and excessive drill wear [2,[16][17][18][19], while the titanium alloys show poor thermal conductivity, high hardness and low elastic modulus [20][21][22][23][24][25], resulting in high cutting forces, excessive machining temperatures and catastrophic tool failures like microchipping or edge fracture. As such, machining of these multilayer stacks with desired quality has been a challenging task in the modern aerospace community.…”

Section: Introductionmentioning

confidence: 99%