Wear performance investigation of PVD coated and uncoated carbide tools during high-speed machining of TiAl6V4 aerospace alloy

Chowdhury, M.S.I.; Bose, Bipasha; Yamamoto, Kenji; Шустер, Л. Ш.; Paiva, José Mario; Fox-Rabinovich, German

doi:10.1016/j.wear.2019.203168

Cited by 44 publications

(23 citation statements)

References 27 publications

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“…Also, with high cutting speed, there will be a reduction in the tool-chip contact length [ 64 ] and friction between tool and workpiece [ 65 ] which help to produce more uniform shearing and chip separation leading to a smoother surface. At low cutting speed, increasing friction between tool and workpiece [ 64 ] increase the possibility of build-up of edge formation resulting in poorer surface finishing [ 52 ]. These results agree with [ 26 ].…”

Section: Resultsmentioning

confidence: 99%

“…Excessive tool wear rates when machining titanium alloys is one of the reasons they are difficult-to-cut materials [ 52 , 53 ], so proper selection of a suitable cutting tool is necessary for machining reliability and high productivity [ 54 ]. Cutting tool materials which remain hard at high temperatures, with high thermal conductivity and high wear resistance are preferred when machining hard-to-cut materials [ 55 ].…”

Section: Introductionmentioning

confidence: 99%

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Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

et al. 2020

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This article presents the results of an experimental investigation into the machinability of Ti6Al4V alloy during hard turning, including both conventional and high-speed machining, using polycrystalline diamond (PCD) inserts. A central composite design of experiment procedure was followed to examine the effects of variable process parameters; feed rate, cutting speed and depth of cut (each at five levels) and their interaction effects on surface roughness and cutting temperature as process responses. The results revealed that cutting temperature increased with increasing cutting speed and decreasing feed rate in both conventional and high-speed machining. It was found that high-speed machining showed an average increase in cutting temperature of 65% compared with conventional machining. Nevertheless, high-speed machining showed better performance in terms of lower surface roughness despite using higher feed rates compared to conventional machining. High-speed machining of Ti6Al4V showed an improvement in surface roughness of 11% compared with conventional machining, with a 207% increase in metal removal rate (MRR) which offered the opportunity to increase productivity. Finally, an inverse relationship was verified between generated cutting temperature and surface roughness. This was attributed mainly to the high cutting temperature generated, softening, and decreasing strength of the material in the vicinity of the cutting zone which in turn enabled smoother machining and reduced surface roughness.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

et al. 2020

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“…At temperatures of around 450–500 °C, this compound melts [ 34 , 35 ] and forms a liquid lubricant which greatly improves the frictional conditions. Coefficient of friction (COF) values drop at operating temperatures within 450–680 °C [ 36 ], Figure 4 b. As a result, built-up size is greatly reduced (SEM images in Figure 2 ) and control over the built-up edge formations is thereby established.…”

Section: Case Studiesmentioning

confidence: 99%

“… Worn surface of TiB2 coated inserts: ( a ) high resolution B1s X-ray Photoelectron spectrum related to ( b ) COF data vs. temperature. Reproduced from [ 28 , 36 ], with permission from Elsevier, 2017 and 2020. …”

Section: Figurementioning

confidence: 99%

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Effect of the Adaptive Response on the Wear Behavior of PVD and CVD Coated Cutting Tools during Machining with Built Up Edge Formation

et al. 2020

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The relationship between the wear process and the adaptive response of the coated cutting tool to external stimuli is demonstrated in this review paper. The goal of the featured case studies is to achieve control over the behavior of the tool/workpiece tribo-system, using an example of severe tribological conditions present under machining with intensive built-up edge (BUE) formation. The built-ups developed during the machining process are dynamic structures with a dual role. On one hand they exhibit protective functions but, on the other hand, the process of built-up edge formation is similar to an avalanche. Periodical growth and breakage of BUE eventually leads to tooltip failure and catastrophe of the entire tribo-system. The process of BUE formation is governed by the stick–slip phenomenon occurring at the chip/tool interface which is associated with the self-organized critical process (SOC). This process could be potentially brought under control through the engineered adaptive response of the tribo-system, with the goal of reducing the scale and frequency of the occurring avalanches (built-ups). A number of multiscale frictional processes could be used to achieve this task. Such processes are associated with the strongly non-equilibrium process of self-organization during friction (nano-scale tribo-films formation) as well as physical–chemical and mechanical processes that develop on a microscopic scale inside the coating layer and the carbide substrate. Various strategies for achieving control over wear behavior are presented in this paper using specific machining case studies of several hard-to-cut materials such as stainless steels, titanium alloy (TiAl6V4), compacted graphitic iron (CGI), each of which typically undergoes strong built-up edge formation. Various categories of hard coatings deposited by different physical vapor deposition (PVD) and chemical vapor deposition (CVD) methods are applied on cutting tools and the results of their tribological and wear performance studies are presented. Future research trends are outlined as well.

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High-Speed Machining for Aerospace Materials

Shubin,

Jahan

2024

Sustainable Aviation

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Wear performance investigation of PVD coated and uncoated carbide tools during high-speed machining of TiAl6V4 aerospace alloy

Cited by 44 publications

References 27 publications

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

Effect of the Adaptive Response on the Wear Behavior of PVD and CVD Coated Cutting Tools during Machining with Built Up Edge Formation

High-Speed Machining for Aerospace Materials

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