Research on breakage characteristics in side milling of titanium alloy with cemented carbide end mill

Abstract

Aiming at the breakage of tool and low precision of the machined surface in the high-speed milling process of titanium alloy, damage mechanics is used to reveal the formation mechanism of tool fatigue breakage during the milling and determine the critical condition of tool breakage. Cutting edge chipping caused by random impact fracture during the evolution of tool damage is the main failure form of tool fatigue breakage. Based on continuous damage mechanics, fatigue crack growth theory and sliding crack energy balance equation, the crack growth law of tool material is studied under different cutting impact, and the initial damage value and critical damage value of tool material fracture based on the interval method are obtained. And the impact fracture limit conditions of the end mill edge are established including cutting parameters, material hardness, tool damage, tool wear, and cutting impact, which provide a theoretical basis for determining the cutting parameters. A titanium alloy milling experiment is carried out to define the impact damage morphology of the tool in different states after the tool is damaged. The obtained tool safety area range is verified, and the research results provide parameter optimization for the high-speed and high-efficiency milling titanium alloy process.

Safety in Rough Milling of Magnesium Alloys Using Tools with Variable Cutting Edge Geometry

“…Generally, it can be claimed that the temperature generated in the cutting zone is inextricably linked to chip formation time, because at a later stage of the milling process the chip temperature does not increase. The problem of short-term ignition during milling and its infrared measurement [3,4] has also been investigated in studies devoted to the machinability of other construction materials such as titanium or nickel alloys [5][6][7][8].…”

“…Similar studies (on chip temperature in the cutting zone) have also been conducted for other grades of construction materials used in industry. For example, chip ignition may occur during milling titanium alloys [5][6][7][8] and nickel alloys. Although the machining conditions and machining parameter ranges are considerably different from those used for light alloys, the risk of chip ignition and resulting machining problems are very similar.…”

Surface feature and material removal in ultrasonic vibration-assisted slot-milling of Ti–6Al–4 V titanium alloy

“…For structural components of Ti-6Al-4V, the material removal by machining can be up to 95% of the total workpiece mass [6]. The machining of workpieces made of titanium alloys inevitably involves corner machining and slot machining, which requires the uniform removal of material in the slot bottom, while at the same time requiring the quality of the machining in the slot sidewalls [7]. However, it is di cult to guarantee the quality of both the slot bottom and the slot sidewall with conventional machining methods [6,8].…”