Tool Life Prediction by Response Surface Methodology for End Milling Titanium Alloy Ti-6Al-4V Using PCD Inserts

This paper presents an approach to establish models for tool life in end milling of titanium alloy Ti-6AI-4V using PCD inserts under dry conditions. Small central composite design (CCD) was employed in developing the tool life model in relation to primary cutting parameters such as cutting speed, axial depth of cut and feed. Flank wear has been considered as the criteria for tool failure and the wear was measured under a Hisomet II Toolmaker's microscope. Further testing was stopped and an insert rejected when an average flank wear greater than 0.30 mm was achieved. Design-expert version 6.0.8 software was applied to establish the first-order and the second-order models and develop the contours. The adequacy of the predictive model was verified using analysis of variance (ANOVA) at 95% confidence level

Theoretical and experimental investigation in prediction of tool life in preheated machining of AISI 02 hardened steel

The tool life of TiAlN coated carbide tools was investigated at various combinations of cutting speed, feed and preheating temperature in end milling of AISI 02 hardened steel under room temperature and preheated machining conditions. Sufficient number of experiments was conducted based on the central composite design (CCD) which was adopted by response surface methodology (RSM) to generate tool life prediction values. The experimental results show that preheated machining led to appreciable increasing tool life compared to room temperature machining. The percentage of tool life increase was between 190-315 % depending on preheating temperature. Preheating of the work material with higher heating temperatures (250-450 0c) gives significant improvement in terms of tool lif

Improved tool life in end milling Ti-6Al-4V through workpiece preheating

This paper presents the investigation of tool life improvement in end-milling of Titanium Alloy Ti-6Al-4V through workpiece preheating. End milling tests were conducted on Vertical Machining Centre with full immersion cutting. Induction heating was utilized during end milling for preheating. The titanium alloy Ti-6Al-4V bar was used as the workpiece. Machining was performed with a 20 mm diameter end-mill tool holder fitted with one PCD inserts. All of the experiments were run under room temperature and preheating condition at 315, 450, and 650ºC. Flank wear has been considered as the criterion for tool failure and the wear was measured using a Hisomet II Toolmaker’s microscope. Tests were conducted until an insert was rejected when an average flank wear greater than 0.30 mm was recorded. Cutting force and torque measurements were conducted using the Kistler Rotating Cutting Force Dynamometer. Vibration during cutting was captured using an online vibration monitoring system. Scanning electron microscope (SEM) was also used to investigate the wear morphology. The results led to conclusions that workpiece preheating significantly increases the tool life of PCD inserts in end-milling of Titanium Alloy Ti-6Al-4V

Prediction of tool life in end milling of hardened steel AISI D2

Most published research works on the development of tool life model in machining of hardened steels have been mainly concerned with the turning process, whilst the milling process has received little attention due to the complexity of the process. Thus, the aim of present study is to develope a tool life model in end milling of hardened steel AISI D2 using PVD TiAIN coated carbide cutting tool. The hardness of AISI D2 tool lies within the range of 56-58 HRC. The independent variables or the primary machining parameters selected for this experiment were the cutting speed, feed, and depth of cut. First and second order models were developed using Response Surface Methodology (RSM). Experiments were conducted within specified ranges of the parameters. Design-Expert 6.0 software was used to develop the tool life equations as the predictive models. The predicted tool life results are presented in terms of both 1st and 2nd order equations with the aid of a statistical design of experiment software called Design-Expert version 6.0. Analysis of variance (ANOVA) has indicated that both models are valid in predicting the tool life of the part machined under specified condition and the prediction of average error is less than 10%

Tool life assessment in end milling titanium alloy (Ti-6Al-4V) using PCD inserts

This paper presents the investigation for assessment of tool life of PCD inserts in end milling of titanium alloy Ti-6A1-4V under dry conditions. Small central composite design (CCD) was employed to design the experiments and to develop the models which correlate tool life and the primary cutting parameters such as cutting speed, axial depth of cut and feed values. The range which is used in this study for cutting speed, axial depth of cut, and feed, are 80.5-200 m/min, 0.5-2.0 mm, and 0.05-0.15 mm/tooth, respectively. Design expert package software was employed to establish the tool life models and the adequacy of the models were verified using analysis of variance at 95% of confidence interval. From the models, it was affirmed that cutting speed has the most significant effect on tool life, followed by feed and axial depth of cut

Improved tool life in end milling ti-6al-4v through workpiece preheating

This paper presents the investigation of tool life improvement in end-milling of Titanium Alloy Ti-6Al-4V through workpiece preheating. End milling tests were conducted on Vertical Machining Centre with full immersion cutting. Induction heating was utilized during end milling for preheating. The titanium alloy Ti-6Al-4V bar was used as the workpiece. Machining was performed with a 20 mm diameter end-mill tool holder fitted with one PCD inserts. All of the experiments were run under room temperature and preheating condition at 315, 450, and 650°C. Flank wear has been considered as the criterion for tool failure and the wear was measured using a Hisomet II Toolmaker's microscope. Tests were conducted until an insert was rejected when an average flank wear greater than 0.30 mm was recorded. Cutting force and torque measurements were conducted using the Kistler Rotating Cutting Force Dynamometer. Vibration during cutting was captured using an online vibration monitoring system. Scanning electron microscope (SEM) was also used to investigate the wear morphology. The results led to conclusions that workpiece preheating significantly increases the tool life of PCD inserts in end-milling of Titanium Alloy Ti-6Al-4V

Tool life prediction by response surface methodology in end milling titanium alloy Ti-6A1-4V using uncoated WC-Co inserts

This paper presents an approach to establish models for tool life in end milling of titanium alloy Ti–6Al– 4V using uncoated carbide inserts under dry conditions. Small central composite design (CCD) was employed in developing the tool life model in relation to primary cutting parameters such as cutting speed, axial depth of cut and feed. Flank wear has been considered as the criteria for tool failure and the wear was measured under a Hisomet II Toolmaker’s microscope. Further testing was stopped and an insert rejected when an average flank wear greater than 0.30 mm was achieved. Design-expert version 6.0.8 software was applied to establish the first-order and the second-order model and develop the contours. The adequacy of the predictive model was verified using analysis of variance (ANOVA) at 95% confidence level

Tool life prediction by response surface methodology in end milling titanium alloy Ti-6Al-4V using uncoated WC-Co inserts

This paper presents an approach to establish models for tool life in end milling of titanium alloy Ti–6Al– 4V using uncoated carbide inserts under dry conditions. Small central composite design (CCD) was employed in developing the tool life model in relation to primary cutting parameters such as cutting speed, axial depth of cut and feed. Flank wear has been considered as the criteria for tool failure and the wear was measured under a Hisomet II Toolmaker’s microscope. Further testing was stopped and an insert rejected when an average flank wear greater than 0.30 mm was achieved. Design-expert version 6.0.8 software was applied to establish the first-order and the second-order model and develop the contours. The adequacy of the predictive model was verified using analysis of variance (ANOVA) at 95% confidence level