High Speed Machining of Ti-alloys-A critical Review (original) (raw)
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A Review on High-Speed Machining of Titanium Alloys
JSME International Journal Series C, 2006
Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very difficult to machine them due to their poor machinability. When machining titanium alloys with conventional tools, the tool wear rate progresses rapidly, and it is generally difficult to achieve a cutting speed of over 60 m/min. Other types of tool materials, including ceramic, diamond, and cubic boron nitride (CBN), are highly reactive with titanium alloys at higher temperature. However, binder-less CBN (BCBN) tools, which do not have any binder, sintering agent or catalyst, have a remarkably longer tool life than conventional CBN inserts even at high cutting speeds. In order to get deeper understanding of high speed machining (HSM) of titanium alloys, the generation of mathematical models is essential. The models are also needed to predict the machining parameters for HSM. This paper aims to give an overview of recent developments in machining and HSM of titanium alloys, geometrical modeling of HSM, and cutting force models for HSM of titanium alloys.
High-speed machining of titanium alloys using the driven rotary tool
International Journal of Machine Tools and Manufacture, 2002
Machining of titanium at high cutting speeds such as from 4 m/s to 8 m/s is very challenging. In this paper, a new generation of driven rotary lathe tool was developed for high-speed machining of a titanium alloy, Ti-6Al-4V. The rotary tool was designed and fabricated based on the requirements of compact structure, sufficient stiffness and minimal edge runout. Cylindrical turning experiments were conducted using the driven rotary tool (DRT) and a stationary cutting tool with the same insert, for comparison in the high-speed machining of Ti-6Al-4V. The results showed that the DRT can significantly increase tool life. Increase in tool life of more than 60 times was achieved under certain conditions. The effects of the rotational speed of the insert were also investigated experimentally. Cutting forces were found to decline slightly with increase of the rotational speed. Tool wear appears to increase with the rotational speed in a certain speed range.
Machining of titanium and its alloys—a review
ARCHIVE: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 1989-1996 (vols 203-210), 1990
Even though a new generation of tool materials is now available which is revolutionizing machinability of a large number of work materials, the machining of titanium continues to be a problem. In the present paper an analysis of the main machining problems, chip formation, tool wear and wear mechanisms, are presented. Alternative methods of machining such expensive and difficult-to-machine materials are also indicated; these include the use of rotary and ledge tools along with ultrasonic assistance.
An overview of conventional and non-conventional techniques for machining of titanium alloys
Manufacturing Review
Machining is one of the major contributors to the high cost of titanium-based components. This is as a result of severe tool wear and high volume of waste generated from the workpiece. Research efforts seeking to reduce the cost of titanium alloys have explored the possibility of either eliminating machining as a processing step or optimising parameters for machining titanium alloys. Since the former is still at the infant stage, this article provides a review on the common machining techniques that were used for processing titanium-based components. These techniques are classified into two major categories based on the type of contact between the titanium workpiece and the tool. The two categories were dubbed conventional and non-conventional machining techniques. Most of the parameters that are associated with these techniques and their corresponding machinability indicators were presented. The common machinability indicators that are covered in this review include surface roughne...
Machinability and Machining of Titanium Alloys: A Review
Materials Forming, Machining and Tribology, 2014
This chapter reviews the main difficulties impairing the machinability of titanium alloys. The overview of machinability of titanium alloys is presented with respect to the following performance criteria: cutting tool wear/tool life, cutting forces, chip formation, and surface integrity attributes, mainly surface roughness. Thereafter, the effects of various lubrication and cooling methods in machining titanium alloys is also discussed. Furthermore, a case study on the metallic particle emission when machining Ti-6A1-4V is also presented.
A Review on Recent Studies: Non-Traditional Machining of Titanium Alloys
2020
Till now titanium and its alloys used in different industrial sectors. Unique material characteristics make it as desirable raw material for the automotive, aerospace, petroleum, chemical, marine and biomedical industries. It requires deformation and fabrication process as difficult-to-cut material. There are several challenges hidden under the processes. Therefore, advanced machining process performance investigation in titanium and its titanium alloys machining has taken part of the research concern. A number of research works has been done in every year to show the research direction. However, most of them are specifically in one machining process. It’s important to have a clear picture of a research area for further research consideration. Therefore, this review aim to study recent articles of non-traditional machining process of titanium and its alloys. The focus of this review was on the contribution for solving existing problems by using non-traditional machining processes, m...
IOP Conference Series: Materials Science and Engineering, 2018
The wonder metal Titanium and its alloys are prime candidate for various automotive, biomedical and aerospace applications due to their good strength-to-weight ratio, biocompatibility and corrosion resistance. Titanium and its alloys are known as difficult-tomachine materials i.e. their machining is challenging. The experimental work reported in the present paper attempts to enhance the machinability of Titanium Grade 4 under the influence of minimum quantity lubrication at high speed conditions. In this work a total of twenty seven experiments has been conducted based on full factorial design of experiment technique. Cutting speed, feed rate, and depth of cut are varied at three levels each and the values of important MQL parameters are fixed. The effects of machining parameters on surface roughness are discussed. Machining at optimum combination of parameters resulted in precision finish with maximum roughness value 2.16 µm and maximum tool flank wear value 0.201 mm. The research results reveal the superiority of MQL over conventional wet cooling to successfully machine Titanium Grade 4 at high speed conditions with sustainability.
A Study on the Sustainable Machining of Titanium Alloy
2016
Titanium and its alloy (Ti-6Al-4V) are widely used in aerospace industries because of their light weight, high specific strength, and corrosion resistance. This study conducted a comparative experimental analysis of the machinability of Ti-6Al-4V for conventional flood coolant machining and sustainable dry machining. The effect of cutting speed, feed rate, and depth of cut on machining performance has been evaluated for both conditions. The machining time and surface roughness were found to be lower in dry machining compared to flood coolant machining. The tool wear was found to be unpredictable, and no significant difference was observed for dry and coolant machining. In a comparison of all the parameters, sustainable dry machining was found to provide better performance in machining Ti-6Al-4V. This study also investigated the machinability of Ti-6Al-4V using coated and uncoated tungsten carbide tools under dry conditions. Tool wear is a serious problem in the machining of titanium alloys in dry conditions. Heat dissipation from the toolworkpiece interface a difficult challenge in dry machining, resulting in the alloying of the workpiece to the tool surface. Dry machining with the coated tool was comparatively faster, and resulted in less tool wear than uncoated tools. Using the Titanium aluminum nitride TiAlN coated carbide tool during dry machining provided a smoother surface finish with lower average surface roughness. The conclusion, therefore, is that the tool coating was found to be effective for the dry machining of titanium alloys.
Titanium alloys and their machinability—a review
Journal of Materials Processing Technology, 1997
Although there have been great advances in the development of cutting tool materials which have significantly improved the machinability of a large number of metallic materials, including cast irons, steels and some high temperature alloys such as nickel-based alloys, no equivalent development has been made for cutting titanium alloys due primarily to their peculiar characteristics. This paper reviews the main problems associated with the machining of titanium as well as tool wear and the mechanisms responsible for tool failure. It was found that the straight tungsten carbide (WC/Co) cutting tools continue to maintain their superiority in almost all machining processes of titanium alloys, whilst CVD coated carbides and ceramics have not replaced cemented carbides due to their reactivity with titanium and their relatively low fracture toughness as well as the poor thermal conductivity of most ceramics. This paper also discusses special machining methods, such as rotary cutting and the use of ledge tools, which have shown some success in the machining of titanium alloys. © 1997 Elsevier Science S.A.
Review on machinability of titanium alloys: the process perspective
Titanium alloys are widely used in the engineering field, namely in the aerospace, automotive and biomedical parts, because of their high specific strength and exceptional corrosion resistance. However, the machinability of titanium alloys is difficult due to their low thermal conductivity and elastic modulus, high hardness at elevated temperature, and high chemical reactivity. This article reviews the state of the art of machinability of titanium alloys, and focuses on the analysis of the process details, namely the especial techniques for cutting improvement, machining forces, chip formation and cutting temperature. The influence of titanium properties on the machinability is also highlighted. Particular attention is given to the turning process of Ti-6Al-4V alloy. The conclusions presented at the end highlight some current trends, disagreement, and research needs.