Progressive tool failure in high-speed dry milling of Ti-6Al-4V alloy with coated carbide tools

Li, Anhai; Zhao, Jun; Luo, Hanbing; Pei, Zhiqiang; Wang, Zeming

doi:10.1007/s00170-011-3408-1

Cited by 93 publications

(40 citation statements)

References 21 publications

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“…It is very important to acquire a deep understanding of mechanical fatigue characteristics of WC-Co alloys, because cemented carbide cutting tools are generally applied under strong cyclic stresses in machining processes [2,3]. Unfortunately, there has been a lack of reliable laboratory test standards or methods to evaluate the mechanical fatigue behavior and to choose suitable compositions that are matched to the performance requirements [4].…”

Section: Introductionmentioning

confidence: 99%

Three-point bending fatigue behavior of WC–Co cemented carbides

Zhao

Wang

et al. 2013

Materials & Design

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Section: Introductionmentioning

confidence: 99%

Three-point bending fatigue behavior of WC–Co cemented carbides

Zhao

Wang

et al. 2013

Materials & Design

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“…This involves an increase of the load and of the temperature on the cutting tool up to its extreme abrasion. [3][4][5] It is a typical alpha-beta titanium alloy. 6 Tool wear in cutting processes is defined as the amount of volume loss of tool material on the contact surfaces due to the interactions between the tool, chip and workpiece.…”

Section: Introductionmentioning

confidence: 99%

Cutting force, tool life and surface integrity in milling of titanium alloy Ti-6Al-4V with coated carbide tools

Polini

Turchetta

2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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Titanium alloys are widely used in aeronautics that demands a good combination of high strength, good corrosion resistance and low mass. The mechanical properties lead to challenges in machining operations, such as high process temperature as well as rapidly increasing tool wear. In this work, three carbide end mills have been used in machining of titanium alloy Ti-6Al-4V. The first tool is coated with TiAl; the second and the third are coated with multi-layers or with a single layer of TiAlN. The cutting force and the tool life have been experimentally investigated and put into relationship with the process parameters under dry cutting condition. The quality of the machined surfaces has been evaluated by measuring the roughness of the machined surfaces. Finally, the correlation among cutting force variation, tool wear propagation and surface roughness has been analyzed and discussed. These three tools demonstrate to be able to maintain their hardness and other mechanical properties at the high cutting temperatures that they encountered.

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“…However, as a result of the high temperature, limited tool life, and intense fire hazard, it is extremely difficult to apply higher cutting speed than 500 m/min in Ti-6Al-4V milling using the coated carbide cutting tool. 25,26 As per many research works, the cemented carbide tools cannot withstand very high cutting speed even being coated by TiAlN-TiN (or other typical coating materials) due to the softening effect at high cutting temperature and the oxidation of TiN above 500°C, but it has been reported recently that the possibility of ultra-high-speed milling may be achieved with coated carbide tools in case of small depth of cuts and fairish feed rates to acquire relatively low cutting temperature rise. 27 So, in order to explore the possibility of high-and ultra-high-speed face milling of Ti-6Al-4V alloy and to investigate the cutting performance of coated cemented carbide tool under high and even ultra-high cutting speeds, the face end milling experiments of titanium alloy were carried out at small depth of cuts and a low feed rate, ensuring that these values are small enough to contribute less thermal effect at further higher cutting speed levels.…”

Section: Introductionmentioning

confidence: 99%

Effect of cutting speed on chip formation and wear mechanisms of coated carbide tools when ultra-high-speed face milling titanium alloy Ti-6Al-4V

Zhao

Hou

2017

Advances in Mechanical Engineering

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Chip morphology and its formation mechanisms, cutting force, cutting power, specific cutting energy, tool wear, and tool wear mechanisms at different cutting speeds of 100-3000 m/min during dry face milling of Ti-6Al-4V alloy using physical vapor deposition-(Ti,Al)N-TiN-coated cemented carbide tools were investigated. The cutting speed was linked to the chip formation process and tool failure mechanisms of the coated cemented cutting tools. Results revealed that the machined chips exhibited clear saw-tooth profile and were almost segmented at high cutting speeds, and apparent degree of saw-tooth chip morphology occurred as cutting speed increased. Abrasion in the flank face, the adhered chips on the wear surface, and even melt chips were the most typical wear forms. Complex and synergistic interactions among abrasive wear, coating delamination, adhesive wear, oxidation wear, and thermal mechanical-mechanical impacts were the main wear or failure mechanisms. As the cutting speed was very high (.2000 m/min), discontinuous or fragment chips and even melt chips were produced, but few chips can be collected because the chips easily burned under the extremely high cutting temperature. Large area flaking, extreme abrasion, and serious adhesion dominated the wear patterns, and the tool wear mechanisms were the interaction of thermal wear and mechanical wear or failure under the ultra-high frequency and strong impact thermo-mechanical loads.

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Progressive tool failure in high-speed dry milling of Ti-6Al-4V alloy with coated carbide tools

Cited by 93 publications

References 21 publications

Three-point bending fatigue behavior of WC–Co cemented carbides

Three-point bending fatigue behavior of WC–Co cemented carbides

Cutting force, tool life and surface integrity in milling of titanium alloy Ti-6Al-4V with coated carbide tools

Effect of cutting speed on chip formation and wear mechanisms of coated carbide tools when ultra-high-speed face milling titanium alloy Ti-6Al-4V

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