FE Simulation of Cryogenic Assisted Machining of Ti Alloy (Ti6AI4V)

2015 ◽  
Author(s):  
Vivek Bajpai ◽  
Ineon Lee ◽  
Hyung Wook Park
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Cutting Forces ◽  
Turbine Blades ◽  
Chip Morphology ◽  
Machining Process ◽  
Burr Formation ◽  
Dry Machining ◽  
Cryogenic Machining ◽  
Ti Alloys

Titanium alloys are well-known material because of the excellent mechanical/chemical properties, corrosion resistance and light weight. These alloys are widely used in the high performance applications such as; aerospace, aviation, bio-implants, turbine blades etc. Machining is commonly used to create products out of Ti alloys. Despite of good material properties, Ti alloys have low thermal conductivity, poor machinability, burr formation, high machining temperature, tool wear and poor machinability. The tool wear and high machining temperature can be controlled through coolant. Cryogenic fluid (liquid nitrogen) is a common material used as coolant in various machining process. The current work is focused on the modeling of cryogenic machining on titanium alloy (Ti6Al4V). Dry machining and cryogenic machining processes are modeled for the chip formation and cutting forces in 2D. Experimental works have been performed to validate the model based on the cutting forces and chip morphology. It is showed that the model is capturing the process, evident by the cutting forces and the chip morphology. The error in prediction is limited to 18%. Model showed that the cutting forces are increasing in cryogenic machining due to the increased strength of the workpiece at low temperature. Chip formation is well captured by the current model. Shear band width have been captured in dry machining. Chip curling has been captured at dry and cryogenic machining. It is expected that the model can further useful in the selection of cryogenic process parameter, such as, flow rate, application techniques etc.

Cryogenic Machining of Titanium Ti-5553 Alloy

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Yusuf Kaynak ◽  
Armin Gharibi
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Machining Process ◽  
Dry Machining ◽  
Cryogenic Machining ◽  
Machining Performance ◽  
Wide Range ◽  
New Generation

Titanium alloy Ti-5Al-5V-3Cr-0.5Fe (Ti-5553) is a new generation of near-beta titanium alloy that is commonly used in the aerospace industry. Machining is one of the manufacturing methods to produce parts that are made of this near-beta alloy. This study presents the machining performance of new generation near-beta alloys, namely, Ti-5553, by focusing on a high-speed cutting process under cryogenic cooling conditions and dry machining. The machining experiments were conducted under a wide range of cutting speeds, including high speeds that used liquid nitrogen (LN2) and carbon dioxide (CO2) as cryogenic coolants. The experimental data on the cutting temperature, tool wear, force components, chip breakability, dimensional accuracy, and surface integrity characteristics are presented and were analyzed to evaluate the machining process of this alloy and resulting surface characteristics. This study shows that cryogenic machining improved the machining performance of the Ti-5553 alloy by substantially reducing the tool wear, cutting temperature, and dimensional deviation of the machined parts. The cryogenic machining also produced shorter chips as compared to dry machining.

Investigation on Chip Formation during Machining Using Finite Element Modeling

2012 ◽  
Vol 505 ◽  
pp. 31-36 ◽  
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed ◽  
A.A. Oshkour
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Machining Process ◽  
Element Modeling ◽  
Segmented Chip ◽  
Cutting Speeds

Titanium alloys are desirable materials for aerospace industry because of their excellent combination of high specific strength, lightweight, fracture resistant characteristics, and general corrosion resistance. Therefore, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. The chips are generally classified into four groups: continuous chips, chips with built-up-edges (BUE), discontinuous chips and serrated chips. . The chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The mechanics of segmented chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V are studied in detail with the aid of high-speed imaging of the chip formation zone. The finite element model of chip formation of Ti–6Al–4V is suggested as a discontinuous type chip at lower cutting speeds developing into a continuous, but segmented, chip at higher cutting speeds. The prediction by using finite-element modeling method and simulation process in machining while create chips formation can contribute in reducing the cost of manufacturing in terms of prolongs the cutting tool life and machining time saving.

Study on the machining process of micro V-shaped groove by using a revolving tip

2017 ◽  
Vol 232 (9) ◽  
pp. 1523-1537
Author(s):  
Bo Xue ◽  
Yongda Yan ◽  
Gaojie Ma ◽  
Zhenjiang Hu
Keyword(s):  
Cutting Forces ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Machining Process ◽  
Burr Formation ◽  
Uncut Chip Thickness ◽  
Machined Surface ◽  
Advantages And Disadvantages

This paper proposed a machining method for micro V-shaped grooves, which was achieved by introducing the revolving trajectory on the basis of tip scratching process. By coordinating the revolving direction and the tip orientation, four kinds of revolving scratches were developed which had the revolving radii larger than the groove depths. It was found that there were two revolving scratches among these four being able to eliminate the side burrs and produce much smaller cutting forces during machining grooves compared to the traditional scratch, respectively named as the up-milling of face-forward and the down-milling of edge-forward. By considering the tip geometry in the traditional scratching process, the burr formation has been studied which was mainly affected by the effect of chip interference and the amount of uncut chip thickness. By analyzing the machining trajectory, the undeformed chip, the machined surface and the chip morphology, the reason why the up-milling of face-forward and the down-milling of edge-forward had good performances for machining V-grooves was elucidated in detail. Meanwhile, the differences between these two revolving scratches were discussed, and their advantages and disadvantages were also given.

The Influence of Cryogenic Coolants in Machining of Ti–6Al–4V

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
B. Dilip Jerold ◽  
M. Pradeep Kumar
Keyword(s):  
Carbon Dioxide ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Fluids ◽  
Cryogenic Machining ◽  
The Past ◽  
Carbon Dioxide Co2 ◽  
Made In

Machining of titanium alloy Ti–6Al–4V is a challenging task because of the greatly increased cutting temperature that results in short tool life. Numerous attempts have been made in the past by employing various cutting fluids for machining purpose, including liquid nitrogen (LN2) as the cryogenic coolant. This study deals with the influence of cryogenic coolants, especially LN2 and carbon dioxide (CO2), in machining of Ti–6Al–4V and its effects on cutting temperature, cutting forces, surface roughness, chip morphology, and tool wear. The results obtained in cryogenic machining are compared with that of dry and wet machining. Cutting temperature was reduced to an extent of 36% and 47% in cryogenic CO2 machining and cryogenic LN2 machining in comparison with wet machining. The application of CO2 produced reduced cutting forces up to 24% and improved surface finish up to 48% compared to cryogenic LN2 machining. It also produced better chip control and minimized tool wear than dry, wet, and LN2 machining.

Machinability Study on Hard Milling of Ultra-High Strength Steel 30Cr3SiNiMoVA

2012 ◽  
Vol 565 ◽  
pp. 496-502 ◽  
Author(s):  
Ming Chen ◽  
Jin Yang Xu ◽  
Zhi Qiang Liu ◽  
Qing Long An
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
High Strength Steel ◽  
Chip Morphology ◽  
High Strength ◽  
Machining Process ◽  
Hard Milling ◽  
Processing Cost ◽  
Ultra High Strength Steel ◽  
Coated Carbide

The superior mechanical and physical properties of ultra-high strength steel 30Cr3SiNiMoVA have awarded the material such desirable and increasing demands in aerospace and aviation industries. Due to its excellent properties, 30Cr3SiNiMoVA is usually classified as a difficult-to-cut material. The machining process of ultra-high strength steel is often characterized by high cutting forces, low surface finish and severe tool wear. In actual production, hard cutting which is a profitable alternative to finish grinding is usually employed in order to improve machining efficiency and reduce processing cost. Therefore, this research concerns the machinability evaluation in hard milling of 30Cr3SiNiMoVA by using TiAlN coated carbide tools. The machinability of the steel was investigated with respect to cutting forces, surface roughness, chip morphology and tool wear, respectively. Finally, a comparative test was also conducted between hard milling and grinding process. The results pointed out that hard milling and coated tools were suitable, beneficial and effective for manufacturing ultra-high strength steel 30Cr3SiNiMoVA.

Cutting Force Modeling When Milling Nickel-Base Superalloys

2010 ◽  
Author(s):  
Andrew J. Henderson ◽  
Cristina Bunget ◽  
Thomas R. Kurfess
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Gas Turbines ◽  
Elevated Temperatures ◽  
Base Alloy ◽  
Turbine Blades ◽  
Subsurface Damage ◽  
Machining Process ◽  
Nickel Base Superalloys ◽  
Nickel Base

Superalloys are a relatively new class of materials that exhibit high mechanical strength, ductility, creep resistance at high operating temperatures, high fatigue strength, and typically superior resistance to corrosion and oxidation even at elevated temperatures. These properties make superalloys ideal for applications in aircraft, cryogenic tanks, submarines, nuclear reactors, and petrochemical equipment. In the aerospace industry, the most commonly used superalloy is the nickel-base alloy and it accounts for 30–50% of the total material required in the manufacturing of the aircraft engine. It is used for rotating parts of gas turbines such as blades and disks, engine mounts, turbine casings and components for rocket motors and pumps. To make full use of nickel-base superalloys, a machining process must be developed that is capable of controlling and identifying tool wear, and identifying the onset of subsurface damage and controlling its formation during processing. To accomplish this, a model relating process characteristics and cutting parameters need to be developed. Due to high tool wear, the cutting forces increase drastically during machining, thus making impossible to estimate the forces with existing models. This research proposes an update to the specific cutting forces model taking into consideration rapid tool wear. As milling is the most common machining processes used to cut superalloys (e.g., turbine blades), it is specifically targeted by this research. Experiments were conducted under different cutting conditions to observe the cutting characteristics of nickel-base superalloys. Empirical observations were used to formulate updated coefficients. Later this model will be applied for real-time control of the process results, such as geometry, tool wear and subsurface damage, and also for estimation and control of other quantities such as force, deflection, surface quality and energy consumed. This will provide new insights into machining these advanced alloys.

scholarly journals Towards Dry Machining of Titanium-Based Alloys: A New Approach Using an Oxygen-Free Environment

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1161
Author(s):  
Hans Jürgen Maier ◽  
Sebastian Herbst ◽  
Berend Denkena ◽  
Marc-André Dittrich ◽  
Florian Schaper ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Wear Mechanism ◽  
Chip Formation ◽  
Cutting Forces ◽  
High Vacuum ◽  
Argon Atmosphere ◽  
Dry Machining ◽  
New Approach ◽  
Underlying Mechanisms ◽  
Free Environment

In the current study, the potential of dry machining of the titanium alloy Ti-6Al-4V with uncoated tungsten carbide solid endmills was explored. It is demonstrated that tribo-oxidation is the dominant wear mechanism, which can be suppressed by milling in an extreme high vacuum adequate (XHV) environment. The latter was realized by using a silane-doped argon atmosphere. In the XHV environment, titanium adhesion on the tool was substantially less pronounced as compared to reference machining experiments conducted in air. This goes hand in hand with lower cutting forces in the XHV environment and corresponding changes in chip formation. The underlying mechanisms and the ramifications with respect to application of this approach to dry machining of other metals are discussed.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

scholarly journals Online Tool Wear Monitoring by the Analysis of Cutting Forces in Transient State for Dry Machining of Ti6Al4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 1014 ◽  
Author(s):  
Sánchez Hernández ◽  
Trujillo Vilches ◽  
Bermudo Gamboa ◽  
Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Transient State ◽  
Cutting Parameters ◽  
Dry Machining ◽  
Crater Wear ◽  
Force Amplitude

In this work, the analysis of the cutting speed and feed rate influence on tool wear and cutting forces in Ti6Al4V alloy dry machining is presented. The study has been focused on the machining in a transient state. The tool wear mechanisms, tool wear intensity and cutting forces evolution have been analyzed as a function of the cutting parameters. Experimental results show that the main cutting force amplitude exhibits a general trend to increase with both cutting parameters. Crater wear was more evident at high cutting speeds, whereas flank wear was present on the whole interval of the cutting parameters analyzed. Furthermore, the cutting speed shows a slightly higher influence on crater wear and the feed rate shows a higher influence on flank wear. Finally, several experimental parametric models have been obtained. These models allow predicting the evolution of crater and flank tool wear, as well as the cutting forces, as a function of the cutting parameters. Additionally, a model that allows monitoring the tool wear on the machining transient state as a function of the main cutting force amplitude has been developed.

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