Wear mechanism analysis in milling of Ti-6Al-4V alloy

Abstract

This article presents an investigation into the wear of cutting tool during milling operation of Ti-6Al-4V using H13A carbide inserts. Wear tests were conducted using machining parameters (feed, speed, and depth of cut) falling in the permissible range recommended by the supplier of the inserts. A wear map was created to identify different regions that characterize the tool wear intensity. The wear map revealed a region of avoidance characterized by higher wear for cutting speed of around 55 m/min and feedrate of 0.15 mm/tooth. The Ti:Al ratio reached values between 4:1 and 6:1 for the cutting parameters that resulted in lower–tool wear rate. However, for higher wear rates, the ratio of Ti:Al did not exhibit any stability across the flank wear land. Scanning electron microscope and energy-dispersive x-ray analysis were performed on the worn inserts to identify the high–tool wear regions and material composition at different locations. Titanium aluminides (TiAl and TiAlN) were found just in the low–tool wear regions, and titanium nitride was found across the avoidance region in the wear map. Microscope and x-ray analysis of inserts in the safety zone clearly revealed a built-up edge on the cutting edge of the tools.

Analysis of shear stress promoting void evolution behavior in an α/β Ti alloy with fully lamellar microstructure

“…Depending on the thermo-mechanical treatment of such (α+β) titanium alloy, different microstructures can be obtained, which can lead to different mechanical properties [5][6][7]. Two extreme From the literature it can be noticed that most of researchers' attention was paid on fully equiaxed [8][9][10][11][12][13] or bimodal microstructure [14][15][16] rather than fully lamellar microstructure [17,18].…”

Prediction of surface roughness magnitude in computer numerical controlled end milling processes using neural networks, by considering a set of influence parameters: An aluminium alloy 5083 case study

“…Investigation of the machinability behaviour, chip formation, surface residual stresses and surface characterisation for different material compositionsusing standard types of tools, generally, those proposed from the manufacturers' machinability tables; [10][11][12] Evaluation of alternative types of either end mill finishing or milling machines according to surface quality issues; 13 Prediction through simulation of end milling process parameters, utilising analytical or arithmetical methods; [14][15][16][17] Tool wear issues 18 and their effect on process performance; 19,20 Process performance predictions through appropriate modelling -statistical or mathematical; for example, regression analysis of artificial neural networks (ANNs). 21,22 The mechanisms leading to the formation of surface roughness are very complex and interacting in nature.…”

Research on the cold plasma jet assisted cutting of Ti6Al4V

“…The abrasive scratch and adhesive material are reduced significantly in NPJ atmosphere on the Ti6Al4V surface, which is detected in increased N element than in air or N 2 jet atmospheres. Syed et al [34,35] studied milling of Ti6Al4V alloy and turning Ti6Al4V, and results showed that coating tool with N elements has lower thermal conductivity values to reduce tool wear and enhancing tool life. Hence, high active nitrogen particles in NPJ atmosphere easily formed a chemical reaction to the Ti6Al4V friction surface to generate nitrides, which are beneficial to wear reduction.…”