Tool life of TiAlN PVD coated carbide tool in high-speed end milling of untreated inconel 718 under minimum quantity lubrication condition

This paper presents the tool life of the end milled Inconel 718, which is part of a material that is difficult to be machined. Previous researchers found that tool life in machining aged Inconel 718 is shorter compared with other materials. However, this observation required further investigation. Thus, a raw grade Inconel was proposed in this experiment. The experiments were performed using TiAlN-coated carbide. The studied milling parameters were the cutting speed, Vc, from 90 to 150 m/min; feed rate, fz, from 0.15 to 0.25 mm/rev; depth of cut, ap, from 0.3 to 0.5 mm; and radial depth of cut, ae=1 mm. The application of the cutting fluid used in this experiment was a minimum quantity lubricant, which had the advantage of cooling effectiveness and low consumption of cutting fluid. The results showed that the feed rate, fz, was the primary factor controlling the tool life. The combination of Vc=115 m/min, fz=0.15 mm/tooth, as well as ap=0.5 mm and ae=0.15 mm gave the longest tool life that served 95.38 min in operation

Effect of high-speed parameters on uncoated carbide tool in finish turning titanium Ti-6Al-4V ELI

In this work, the Sandvik uncoated carbide insert, CNGG 120408-SGF-H13A was used as a cutting tool in high-speed turning of titanium alloy Ti-6Al-4V ELI (extra-low interstitial) with hardness of 32 HRC. Wear is one of the problems that cannot be avoided in machining process. Therefore, the objective of this paper was to investigate tool-wear behavior of various cutting-speed values (high-speed range) on the tool life of the cutting tools, especially in finishing titanium alloy. The experiments were performed under flooded coolant condition using water-based mineral-oil. The cutting speeds employed were 120, 170 and 220 m/min. The feed rate was constant at 0.2 mm/rev and the depth of cut was 0.4 mm. Based on the results, the highest cutting speed of 220 m/min caused the highest wear rate. By linking the machine operations and the tool life curves obtained using flank wear data, the wear behavior of uncoated carbide was described

Comparison between Up-milling and Down-milling Operations on Tool Wear in Milling Inconel 718

AbstractThe demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace industry as it is efficient for energy and has excellent properties. In this paper, the experimental studies of tool wear mechanism and tool life in ball nose end milling of Inconel 718 is presented under minimum quantity lubricant (MQL) condition. The evaluations of the results are focusing on the comparison of up-milling and down-milling operations using physical vapor deposition (PVD) - coated carbide inserts. Machining parameters; depth of cut, feed rate and cutting speed are considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear than up-milling operation. Chipping on cutting tool edge was the primary reason that responsible to notch wear with prolong machining

OPTIMIZATION OF TURNING PARAMETERS FOR TITANIUM ALLOY TI-6AL-4V ELI USING THE RESPONSE SURFACE METHOD (RSM)

Titanium alloys are attractive materials due to their uniquely high strength–weight ratio, which is maintained at elevated temperatures. Due to the low machinability of titanium alloys, optimization of machining conditions is crucial. Uncoated carbide tool (CNGG 120408-SGF-H13A) was used to turn the titanium alloy Ti-6Al-4V ELI. In this study, the effects of cutting speed, feed rate, and depth of cut parameters were examined. Cutting-speed range of 120–220 m/min was used under flooded conditions. Response surface method (RSM) with a Box-Behnken design was utilized to set the 17 parameter runs. Analysis shows that cutting speed had the greatest effect on tool life, followed by feed rate and depth of cut. Meanwhile the feed rate was most significant factor for surface roughness, Ra of machined surface rather than cutting speed and depth of cut. Additionally, the optimum machining conditions were determined using RSM for both tool life and Ra to be a high cutting-speed of 220 m/min and a low depth of cut and feed rate of 0.4 mm and 0.1 mm/rev, respectively. Here the tool life gave 14.55 min for predicted value, but the validation thru experimental work produced 13.05 min, and the error about 10.65%. Moreover the surface roughness, Ra value for predicted was 0.529µm, meanwhile the validation gave 0.489 µm. This error was calculated to 7.56%

Temperatures during the dry cutting of titanium alloy using diamond composites with ceramic bonding phases

In this paper the thermal properties of diamond composites with ceramic bonding phases, such as the Ti–Si–C system with nanometric Ti(CN) and TiB₂ are presented. The thermal conductivities of the materials were analyzed by the laser pulse method. In addition, computational simulations of the temperature dependence on the distance from the cutting edge were performed according to the finite element method for the investigated composites, commercial PCD, and hypothetical diamond monocrystal.Досліджено теплові властивості алмазних композитів з керамічними зв’язуючими фазами, таких як системи Ti–Si–C з нанометровим Ti(CN) і TiB₂. Теплопровідності матеріалів проаналізовано за допомогою методу лазерного імпульсу. Крім того, методом скінченних елементів виконано числове моделювання залежності температури від відстані до ріжучої кромки для досліджених композитів, комерційного PCD і гіпотетичного монокристалу алмазу. Розглянуто дві швидкості різання в ході числового обчислення: 100 і 200 м/хв.Исследованы тепловые свойства алмазных композитов с керамическими связующими фазами, таких как системы Ti–Si–C с нанометровым Ti(CN) и TiB₂. Теплопроводности материалов проанализированы с помощью метода лазерного импульса. Кроме того, методом конечных элементов выполнено числовое моделирование зависимости температуры от расстояния до режущей кромки для исследованных композитов, коммерческого PCD и гипотетического монокристалла алмаза. Рассматривали две скорости резки в ходе числового вычисления: 100 и 200 м/мин

Microstructural Investigations of the White and Deformed Layers Close to the Turned Surface of Ti-6Al-4V

In the aircraft industry, along with geometrical and dimensional integrity, the surface integrity of manufactured parts is a necessity. In fact, severe anomalies generated during machining may have a substantial impact on the lifetime of the parts. Nevertheless, these anomalies are not well known in terms of microstructures such as the white layer in titanium alloys. Based on this observation, the present paper deals with microstructural investigations performed on Ti-6Al-4V white and deformed layers generated during turning with a round uncoated carbide insert. The aim of this study is to characterize these anomalies in terms of microstructure and phases. In particular, this study provides a better understanding of metallurgical transformations in the sublayer of machined surfaces through qualitative models