Tool wear characteristics of binderless CBN tools used in high-speed milling of titanium alloys

Wang, Z.G.; Rahman, M.; Wong, Yoke San

doi:10.1016/j.wear.2004.09.066

Cited by 109 publications

(61 citation statements)

References 12 publications

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“…Similar to literature [1,2,8,12], the cutting force decreased with an increase in V c for CMX850. There is a noticeable reduction in cutting force when increasing the cutting speed from V c =100 to V c =200 m/min.…”

Section: Cutting Forcessupporting

confidence: 87%

“…Similarly, research [3] reported a rather satisfactory long tool life (T=381 min) with good surface finish and geometrical accuracy, finish milling titanium compressor blades with PCD at a relatively slower cutting speed (V c =110 m/min). In addition to this, research [2,12] indicated that the performance of binderless cubic boron nitride (BCBN) is a manifestation of the phenomenon envisaged in a study [7], namely that a tool material with sufficiently hot hardness will be able to yield better machining productivity through the utilization of the thermal softening of Ti6Al4V by means of an α-β phase change [13]. This counterintuitive phenomenon has been discussed in the literature [7,13], and it is believed [14] that higher cutting speeds lead to decreasing cutting forces [8] if the cutting material is able to maintain its hot strength, whereas the workpiece material softens at the cutting edge, and chips can be removed more easily.…”

Section: Introductionmentioning

confidence: 96%

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The performance of PCD tools in high-speed milling of Ti6Al4V

Oosthuizen

Akdogan

Treurnicht

2010

Int J Adv Manuf Technol

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Tool performance of conventional tools is poor and a major constraint when used in milling titanium alloys at elevated cutting speeds. At these high cutting speeds, the chemical and mechanical properties of Ti6Al4V cause complex wear mechanisms. In this paper, a fine-grain polycrystalline diamond (PCD) end mill tool was tested, and its wear behavior was studied. The performance of the PCD tool has been investigated in terms of tool life, cutting forces, and surface roughness. The PCD tool yielded longer tool life than a coated carbide tool at cutting speeds above 100 m/min. A slower wear progression was found with an increase in cutting speeds, whereas the norm is an exponential increase in tool wear at elevated speeds. Observations based on scanning electron microscope (SEM) and energy dispersive spectroscopy (EDAX) analysis suggest that adhesion of the workpiece is the wear main type, after which degradation of the tools accelerates probable due to the combined effect of high temperature degradation coupled with abrasion.

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Section: Cutting Forcessupporting

confidence: 87%

Section: Introductionmentioning

confidence: 96%

The performance of PCD tools in high-speed milling of Ti6Al4V

Oosthuizen

Akdogan

Treurnicht

2010

Int J Adv Manuf Technol

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“…Wang et al (23), (24) also used BCBN tools for highspeed milling of titanium alloy Ti6Al4V. The performance and the wear mechanism of the BCBN tool had been investigated when slot milling Ti6Al4V in terms of cutting forces, tool life and wear mechanism.…”

Section: Hsm Of Titanium Alloys With Bcbn Toolsmentioning

confidence: 99%

A Review on High-Speed Machining of Titanium Alloys

Rahman

Wang

Wong

2006

JSME Int. J., Ser. C

211

111

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Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very difficult to machine them due to their poor machinability. When machining titanium alloys with conventional tools, the tool wear rate progresses rapidly, and it is generally difficult to achieve a cutting speed of over 60 m/min. Other types of tool materials, including ceramic, diamond, and cubic boron nitride (CBN), are highly reactive with titanium alloys at higher temperature. However, binder-less CBN (BCBN) tools, which do not have any binder, sintering agent or catalyst, have a remarkably longer tool life than conventional CBN inserts even at high cutting speeds. In order to get deeper understanding of high speed machining (HSM) of titanium alloys, the generation of mathematical models is essential. The models are also needed to predict the machining parameters for HSM. This paper aims to give an overview of recent developments in machining and HSM of titanium alloys, geometrical modeling of HSM, and cutting force models for HSM of titanium alloys.

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“…Therefore, new developments on real-time/process behaviour particularly in machining are continuously arising to establish prognostic monitoring, innovations in tool design and process optimisation. Prior studies were attempted on chip morphology, surface texture and cutting force signatures so as to establish the required tool geometry as well as cutting conditions [1][2][3][4][5]. Cutting tool features like rake angle and clearance angle are established on a broader scale for different materials.…”

Section: Introductionmentioning

confidence: 99%

Extraction of flank wear growth models that correlates cutting edge integrity of ball nose end mills while machining titanium

Ramesh

Siong

2010

Int J Adv Manuf Technol

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The application of titanium alloys are increasingly seen at aerospace, marine, bio-medical and precision engineering due to its high strength to weight ratio and high temperature properties. However, while machining the titanium alloys using solid carbide tools, even with jet infusion of coolant lower tool life was vividly seen. The high temperatures generated at the tool-work interface causes adhesion of work-material on the cutting edges; hence, shorter tool life was reported. To reduce the high tool-work interface temperature positive rake angle, higher primary relief and higher secondary relief were configured on the ball nose end-mill cutting edges. However, after an initial working period, the growth of flank wear facilitates higher cutting forces followed by work-material adhesion on the cutting edges. Therefore, it is important to blend the strength, sharpness and surface integrity on the cutting edges so that the ball nose end mill would demonstrate an extended tool-life. Presently, validation of tool geometry is very tedious as it requires extensive machining experiments. This paper illustrates a new feature-based ball-noseend-mill-work interface model with correlations to the material removal mechanisms by which the tool geometry optimization becomes easier. The data are further deployed to develop a multi-sensory feature extraction/correlation model to predict the performance using wavelet analysis and Wagner Ville distribution. Conclusively, this method enables to evaluate the different ball nose end mill geometry and reduces the product development cycle time.

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Tool wear characteristics of binderless CBN tools used in high-speed milling of titanium alloys

Cited by 109 publications

References 12 publications

The performance of PCD tools in high-speed milling of Ti6Al4V

The performance of PCD tools in high-speed milling of Ti6Al4V

A Review on High-Speed Machining of Titanium Alloys

Extraction of flank wear growth models that correlates cutting edge integrity of ball nose end mills while machining titanium

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