VFCVD diamond-coated cutting tools for micro-machining titanium alloy Ti6Al4V

Jackson, Mark J.; Novakov, Tamara; Whitfield, Michael D.; Robinson, G. W.; Handy, Richard L.; Sein, Htet; Ahmed, Waqar

doi:10.1007/s00170-017-0334-x

Cited by 6 publications

(10 citation statements)

References 30 publications

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“…Analytical models for calculating temperature during machining have been developed over the years by integrating thermodynamic principles, the mechanics of metal cutting, and the thermal properties of cutting tool, workpiece, and the cut chip. [1][2][3][4] The underlying assumptions made show that the mean chip/tool contact temperature during machining is a function of a thermal circuit that includes the workpiece temperature, the temperature rise due to plastic deformation, and frictional interactions on the surface between cut chip and tool edge.…”

Section: Experimental Procedures and Resultsmentioning

confidence: 99%

“…In discussing the role of precision manufacturing for use in producing UAVs, precision micromachining processes involve invoking physical and chemical effects that are particularly detrimental to the cutting tool that is used to deform the workpiece material at high strain rates. [1][2][3] Simulation of the micromachining process allows the engineer to design sustainable machining cycles. Enhanced mathematical models can predict metal flow, which may be difficult to visualize when machining with flood coolant flows.…”

Section: Introductionmentioning

confidence: 99%

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Advanced machining of miniature unmanned aircraft vehicle components using nanostructured cutting tools

Jackson

Burgess

Whitfield

et al. 2020

Journal of Micromanufacturing

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The advanced machining of components used in miniature unmanned aircraft vehicles is the focus of this study. The finite element method (FEM) is used to predict forces and temperatures using cutting tool inserts with a thin nanostructured film of high integrity. Similarity models are used to validate the finite element results and to understand the influence of micromachining parameters on cutting temperatures generated when machining Al 380-0 alloy. The predicted results are compared to experimental forces and temperatures using a three-dimensional piezoelectric function dynamometer and a short-range infra-red wavelength thermal camera. Nanostructured thin layer coatings lower machining forces and temperatures, which are validated through FEM predictions and experimental observations. The experimental results suggest that increasing the cutting tool’s rake angle at higher depths of cut will reduce cutting temperatures, which are predicted using the similarity models for micromachining.

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Section: Experimental Procedures and Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Advanced machining of miniature unmanned aircraft vehicle components using nanostructured cutting tools

Jackson

Burgess

Whitfield

et al. 2020

Journal of Micromanufacturing

Self Cite

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“…The Peclet number Pe depends primarily on ζ and the associated generation of heat governed by progressive plastic compression. 23,24 Another similarity index for micromilling efficiency is defined using the Poletica number (Po), which demonstrates similarity of frictional contact of pairs and requires a knowledge of the uncut chip thickness, rake angle, and the velocity of cut thus,…”

Section: Similarity In Machiningmentioning

confidence: 99%

Similarity and difference in machining at mixed scales using nanostructured coated tools milling hypoeutectoid carbon steel

Jackson,

Robinson,

Whitfield

et al. 2023

Journal of Micromanufacturing

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There are similarities and differences when machining at the microscale and macroscale. One difference is the lack of significant heat generated at the microscale, which means that thermal barrier coatings are largely redundant. However, the mechanisms of wear are similar and different depending on machining parameters. In this study, it is discovered that nanostructured coatings play different roles at mixed scales, which are experimentally determined by measuring tool wear, chemical diffusion, temperature, and forces. The main findings show that macroscale wear is thermal in nature and that microscale wear is primarily tribological. The principal conclusions focus on redesigning microtools and nanostructured coatings to eliminate wear, developing standards that describe the action of microtools, and understanding how to calculate the minimum chip thickness that guarantees the formation of chips rather than burrs.

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“…In addition, they have to meet high precision and quality standards. As such, the production of these light alloys has been extensively studied [ 1 , 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 , 30 , 31 , 32 , 33 ]. Their repair and maintenance has also been thoroughly studied.…”

Section: Introductionmentioning

confidence: 99%

Cutting Parameter Selection for Efficient and Sustainable Repair of Holes Made in Hybrid Mg–Ti–Mg Component Stacks by Dry Drilling Operations

et al. 2018

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Drilling is one of the most common machining operations in the aeronautic and aerospace industries. For assembling parts, a large number of holes are usually drilled into the parts so that they can be joined later by rivets. As these holes are subjected to fatigue cycles, they have to be checked regularly for maintenance or repair, since small cracks or damage in its contour can quickly cause breakage of the part, which can have dangerous consequences. This paper focuses on finding the best combinations of cutting parameters to perform repair and maintenance operations of holes in stacked hybrid magnesium–titanium–magnesium components in an efficient, timely, and sustainable (without lubricants or coolants) manner, under dry drilling conditions. For the machining trials, experiments were designed and completed. A product of a full factorial 23 and a block of two factors (3 × 2) was used with surface roughness as the response variable measured as the mean roughness average. Analysis of variance (ANOVA) was used to examine the results. A set of optimized tool and cutting conditions is presented for performing dry drilling repair operations.

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VFCVD diamond-coated cutting tools for micro-machining titanium alloy Ti6Al4V

Cited by 6 publications

References 30 publications

Advanced machining of miniature unmanned aircraft vehicle components using nanostructured cutting tools

Advanced machining of miniature unmanned aircraft vehicle components using nanostructured cutting tools

Similarity and difference in machining at mixed scales using nanostructured coated tools milling hypoeutectoid carbon steel

Cutting Parameter Selection for Efficient and Sustainable Repair of Holes Made in Hybrid Mg–Ti–Mg Component Stacks by Dry Drilling Operations

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