Study on ultrasonic-assisted drilling of Ti6Al4V using 3-flute drill in the finite element simulation

Wang, Peng; Wang, Dazhong

doi:10.1177/0954406219893001

Cited by 16 publications

(2 citation statements)

References 39 publications

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“…3 However, high strain hardening behavior, extreme chemical affinity, poor thermal conductivity and rapid generation of Built Up Edges (BUE) during machining may be identified as some of the major concerns that severely hamper its machinability. 4 Several machining strategies were adopted by researchers to overcome the machinability related issues of Ti-6Al-4V. The use of an effective lubrication medium was one of the major methods that was adopted to find an effective solution for this problem.…”

Section: Introductionmentioning

confidence: 99%

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

George

Sahu

Dhanish

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Machinability of Ti-6Al-4V, despite its numerous applications, is challenging owing to its poor thermal conductivity, severe chemical affinity and strain hardening characteristics. Although various coating techniques and expensive lubrication strategies have been tried, a significant improvement in tool life characteristics are yet to be achieved. Hence this work aims at suggesting a novel cost-effective and ecofriendly tool treatment technique by exploring the impact of a dual combination of an AlSi-10Mg coating developed by an emerging pre-conditioning technique with the incorporation of micro-textures on tool face to observe significant improvements in tool life and machinability characteristics of the alloy. It was analyzed from the results that while the micro-textures played a vital role in reducing the severe contact stress and machining temperature due to its improved heat transfer by convection, AlSi-10Mg film effectively shielded the cutting edges of the tool by providing a dampening effect along the edges, thereby ensuring improved tool life and enhanced machinability characteristics at the same time. The proposed tool combination was observed to be successful in significantly reducing the flank wear by 35%, 43% and 30% where 75, 253, and 371 µm were observed at 80, 100, and 120 m/min as compared to 117, 449, and 531 µm in the case of uncoated non-textured tool at the same operating conditions. Surface roughness of Ti-6Al-4V also reduced by 25%, 34%, and 37% where 1394, 1168, and 872 nm as compared to plain tool where 1840, 1770, and 1370 nm were recorded. Moreover, average chip curl diameter was observed to be 2.62, 3.36, and 6.49 mm as compared to chips generated by uncoated tools which recorded values of 4.33, 11.9, and 18.87 mm at 80, 100, and 120 m/min respectively.

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Section: Introductionmentioning

confidence: 99%

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

George

Sahu

Dhanish

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…Tribological systems in metalworking were established to detect frictional wear during drill machining. 12,13 Tribological experiments had been conducted to obtain friction coefficients for four lubrication conditions, which could be very helpful in improving the quality of the workpiece. 14 The influence of different angles of tool tip on the drilling quality of Ti6Al4V had been analyzed.…”

Section: Introductionmentioning

confidence: 99%

Study on machinability of three-step drill in drilling Ti6Al4V

Wu¹,

Wang²,

Dai

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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As the research progresses, titanium alloy materials have more applications in aerospace and other fields. However, problems such as chip winding and serious tool wear are easy to occur in the machining process. In this research, the three-step drill has changed the main cutting-edge structure, which is more conducive to chip breakage. Firstly, the drilling force of the three-step drill bit is analyzed, and the alternating stress that makes the chip thickness change is obtained by the cutting-edge structure of the three-step drill bit. The simulation and experiment are verified by each other, and the feasibility of three-step drilling to improve the processing quality is obtained. The results show that the improved drill has good chip breaking performance, low thrust force, and better machining performance compared with the twist drill. In addition, the improved drill can obtain a more complete inner wall of the hole and reasonably improve the surface quality. Through experiments, it is found that changing cutting parameters such as feed rate has different effects on chip thickness, thrust and tool wear. It was found that the drilling force was reduced by drilling Ti6Al4V material with the three-step drill. Moreover, the three-step drill can produce smaller chip thicknesses and make the chip more prone to breakage when compared with the twist drill. The high wear of three-step drill bits can also be better weakened by coating materials.

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Finite element simulation of ultrasonic-assisted machining: a review

Lotfi

Âkbari

2021

Int J Adv Manuf Technol

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Study on ultrasonic-assisted drilling of Ti6Al4V using 3-flute drill in the finite element simulation

Cited by 16 publications

References 39 publications

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

Study on machinability of three-step drill in drilling Ti6Al4V

Finite element simulation of ultrasonic-assisted machining: a review

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