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

Abstract

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.

Multi-Response Optimization in High-Speed Machining of Ti-6Al-4V Using TOPSIS-Fuzzy Integrated Approach

“…High hot strength and hardness promote premature tool wear and failure. In addition, high chemical reactivity and 2 of 14 low thermal conductivity accelerate the tool wear and premature failure [3,4]. Considering that the majority of titanium parts are manufactured by machining processes and have very restricted tolerance and high-quality surface finishing requirements, different industries need to overcome the problems associated with titanium alloy machining.…”

MQL Strategies Applied in Ti-6Al-4V Alloy Milling—Comparative Analysis between Experimental Design and Artificial Neural Networks

“…It has the highest strength-to-weight ratio amongst all structural materials, excellent creep and biocompatibility, a low elastic modulus, and chemical inertness at room temperature [ 11 ]. As a result of these properties, titanium is considered a hard-to-cut material [ 12 ], and the main problems include the fact that the high chemical reactivity makes chips easily adhere to the tool-cutting edge, and the low thermal conductivity (1/6 of that for steel) increases the temperature at the tool’s cutting edge (which can easily reach beyond 1000 °C) [ 13 , 14 , 15 , 16 ]. A low modulus of elasticity and an extreme strength at high temperature generate long ductile chips, a relatively large contact length between the chip and the cutting tool, and a high compressive stress, leading to a poor tool life, or to higher cutting forces [ 17 ].…”

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-based Design and Validation

“…An appropriately controlled machining process enables high productivity and minimizes costs of energy, materials, and tools [11]. This necessitates restrictive cutting conditions to be identified and rigorously applied [11,12].…”

“…An appropriately controlled machining process enables high productivity and minimizes costs of energy, materials, and tools [11]. This necessitates restrictive cutting conditions to be identified and rigorously applied [11,12]. In addition, an appropriate design of a cutting tool is essential to achieve an effective chipping operation and to extend tool life [13,14].…”

“…This results in a higher number of production stops and, therefore, in a dramatic increase of production time. Thus, the chip formation process and chip control using combined cryogenic and minimum quantity lubrication [19,20], applying cryogenic lubrication [7,21], high pressure coolant [2,11] ultrasonic-assisted vibration [15,17], optimization of the processing parameters [10,[22][23][24], and chip breakers [10,14,16] as well as their limitations [25], have been widely studied, both experimentally and by means of simulation. It is widely accepted that the contribution of chip breakers in enhancing the chip fragmentation process is significant.…”