The Effect of Minimal Quantity Lubrication (MQL) on the Surface Roughness of Titanium Alloy Ti-6Al-4V ELI in Turning Process

Haron, Che Hasan Che; Ghani, Jaharah A; Sulaiman, Mohd Amri; Intan, L.R.; Kasim, Mohd Shahir

doi:10.4028/www.scientific.net/amr.146-147.1750

Cited by 7 publications

(5 citation statements)

References 2 publications

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“…A higher cutting speed and lower feed rate gave a superior surface finish. Similar results were reported by Che et al [9] in turning Ti6Al4V ELI (Extra Low Interstitials) alloy under minimum quantity lubrication condition (MQL). They have reported that surface roughness is directly proportional to feed and inversely proportional to the cutting speed.…”

Section: Introductionsupporting

confidence: 88%

Machinability analysis in high speed turning of Ti–6Al–4V alloy and investigation of wear mechanism in AlTiN PVD coated tungsten carbide tool

Muthuswamy¹,

Murugesan²

2021

Eng. Res. Express

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Titanium alloys are one of the most critical and prominently used materials in automotive, aerospace, and biomedical application due to their superior strength to weight ratio. The very property that makes it a suitable material for such applications also makes it challenging to machine. In this study, an attempt has been made to understand the machinability of Ti–6Al–4V titanium alloy at high cutting speeds in turning. A full factorial method and Analysis of Variance (ANOVA) technique were used to conduct 18 different experimental runs and determine the significance of variables that are responsible for the variation in average surface roughness (Ra) and forces. The results show that feed rate is the single most significant factor for Ra, whereas the contribution of feed and depth of cut are more for the forces, followed by cutting speed. Tool life tests were conducted with AlTiN PVD coated tools at three different cutting speeds, and SEM analysis to evaluate the wear mechanism revealed that abrasive wear, notching, and diffusion were predominant which accelerated the wear rate. Although machining studies on Ti6Al4V at low cutting speeds are well established, the novelty of the study is to perform a comprehensive analysis to evaluate the machinability and study wear mechanism using AlTiN coated tungsten carbide tool at high cutting speeds.

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Section: Introductionsupporting

confidence: 88%

Machinability analysis in high speed turning of Ti–6Al–4V alloy and investigation of wear mechanism in AlTiN PVD coated tungsten carbide tool

Muthuswamy¹,

Murugesan²

2021

Eng. Res. Express

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“…Raja and Baskar [21] conducted research on the optimization of machining parameters due to the desired surface roughness. Heron [22], Safari [17], and other authors [2,4,17,23] developed an optimization model for the turning process taking into account factors affecting machining, such as cutting force ( F c ), tool life ( T ), surface roughness ( Ra ), material removal rate, and chip breakability. Surface roughness and chip breakability were selected as optimization criteria due to their importance for the finishing turning process.…”

Section: Introductionmentioning

confidence: 99%

Turning Titanium Alloy, Grade 5 ELI, With the Implementation of High Pressure Coolant

2019

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In the machining of difficult-to-cut alloys, such as titanium-based alloys, the delivery of a cutting fluid with high pressure can increase machining efficiency and improve process stability through more efficient chip breaking and removing. Proper selection of machining conditions can increase the productivity of the process while minimizing production costs. To present the influence of cutting fluid pressure and chip breaker geometry on the chip breaking process for various chip cross-sections Grade 5 ELI titanium alloy turning tests were carried out using carbide tools, H13A grade, with a -SF chip breaker geometry under the cutting fluid pressure of 70 bar. Measurements of the total cutting force components for different cutting speeds, feeds, and cutting depth in finishing turning were carried out. The analysis of the obtained chips forms and the application area of the chip breaker have been presented. It was proved that for small depth of cut (leading to small chip cross-section) the cutting fluid pressure is the main cause of the chip breakage, since the insert chip breaker does not work. On the other hand, for bigger depths of cut where the chip breaker goes in action, the cutting fluid pressure only supports this process. For medium values of depths of cut the strength of chip is high enough so that the pressure of the cutting fluid cannot cause chip breaking. A chip groove is not filled completely so the chip breaker cannot play its role.

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“…Improvement in the machinability of titanium alloys can be achieved by using various techniques from dry machining [16,17] to cooling and lubrication of the cutting zone [18] such as minimum quantity lubrication (MQL) machining [19,20], cryogenic machining or high-pressure Cooling (HPC) machining, i.e., the use of systems enabling feeding of cutting fluid to the cutting zone with increased pressure (from 50 to 355 bar, and even 1000 bar). It was analyzed by many authors, such as Ezugwu et al [21], Çolak [22], Khan et al [23] and Da Silva et al [4].…”

Section: Introductionmentioning

confidence: 99%

“…For example, Cus et al [32] demonstrated the usefulness of genetic algorithms (GA) for online optimization of cutting parameters in the milling process. Heron et al [19] and Wang et al [33] developed an optimization model for the turning process, taking into consideration factors affecting machining, such as: cutting force (F c ), tool life (T), surface roughness (Ra), material removal rate and chip breaking.…”

Section: Introductionmentioning

confidence: 99%

Reduction of Power Consumption by Chip Breakability Control in Ti6Al4V Titanium Alloy Turning

2020

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The paper concerns the problem of energy savings in turning of titanium alloy Ti6Al4V. Since this alloy belongs to difficult to cut materials, there is a problem with chip forming and breaking. The turning process is often supported by implementing a high-pressure cooling (HPC) system. Based on the observations and the adopted chip classification method, the authors proved that it is not necessary to use this method in roughing operations, however it helps with the chips breaking process in finishing operations. A general algorithm for machining optimization due to the chip geometry is presented and described. In the presented case, it was shown that the acceptable chip geometry could be obtained with a reduced power consumption by approximately Pc = 0.5 kW. The authors concluded that it was not necessary to apply cutting data and a coolant system to achieve perfect chip geometry. An acceptable form was often sufficient, while requiring less energy. An additional factor resulting from the operation of systems supporting the cutting process, such as an HPC device, should be taken into account in the formula concerning the energy consumption (EC) of a computerized numerical control (CNC) machine tool.

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The Effect of Minimal Quantity Lubrication (MQL) on the Surface Roughness of Titanium Alloy Ti-6Al-4V ELI in Turning Process

Cited by 7 publications

References 2 publications

Machinability analysis in high speed turning of Ti–6Al–4V alloy and investigation of wear mechanism in AlTiN PVD coated tungsten carbide tool

Machinability analysis in high speed turning of Ti–6Al–4V alloy and investigation of wear mechanism in AlTiN PVD coated tungsten carbide tool

Turning Titanium Alloy, Grade 5 ELI, With the Implementation of High Pressure Coolant

Reduction of Power Consumption by Chip Breakability Control in Ti6Al4V Titanium Alloy Turning

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