Experimental characterization of behavior laws for titanium alloys: application to Ti5553

The aim of this paper is to study the machinability of a new titanium alloy: Ti-5AL-5Mo-5V-3CR used for the production of new landing gear. First, the physical and mechanical properties of this material will be presented. Second, we show the relationship between material properties and machinability. Third, the Ti5553 will be compared to Ti64. Unless Ti64 is α+β alloy group and Ti5553 is a metastable, we have chosen to compare these two materials. Ti64 is the most popular of titanium alloys and many works were been made on its machining. After, we have cited the Ti5553 properties and detailed the behavior laws. They are used in different ways: with or without thermal softening effect or without dynamic terms. The goal of the paper is to define the best cutting force model. So, different models are compared for two materials (steel and titanium alloy). To define the model, two methods exist that we have compared. The first is based on machining test; however the second is based on Hopkinson bar test. These methods allow us to obtain different ranges of strain rate, strain and temperature. This comparison will show the importance of a good range of strain rate, strain and temperature for behavior law, especially in titanium machining

Experimental study of coated carbide tools behaviour: application for Ti-5-5-5-3 turning

The goal of this paper is to study the relation between the input data (conditions and geometry of cut) and answers (wear of tool, forces and cutting temperatures) when machining the Ti-5-5-5-3 alloy treated. This study has shown that the cutting process is different and that the slip forces are preponderates. Compared with other materials, the specific cutting pressure is higher and does not vary according to the cutting speed but depend on feed rate. Moreover, both edge preparation and feed rate have an influence on cutting force direction. Besides, cutting temperatures are high and almost similar to those provided by high speed machining with low cutting speed. Finally, we have shown that failure modes are different from those obtained when machining other titanium alloys. Built-up edge is the most deteriorating phenomenon and no flank wear was met in our study context

Optimization of pocket machining strategy in HSM

Our two major concerns, which should be taken into consideration as soon as we start the selecting the machining parameters, are the minimization of the machining time and the maintaining of the high-speed machining machine in good state. The manufacturing strategy is one of the parameters which practically influences the time of the different geometrical forms manufacturing, as well as the machine itself. In this article, we propose an optimization methodology of the machining strategy for pockets of complex forms. For doing this, we have developed analytic models expressing the feed rate of the cutting tools trajectory. Then, we have elaborated an optimization method based on the analysis of the different critical parameters so as to distinguish the most suitable strategies to calculate the cutting time and define the machine dynamics. To validate our results, we have compared them to the experimental ones and also to those found in literature

Compensation of a ball end tool trajectory in complex surface milling

This work is consecrated to the minimising of machining errors based on a method for the compensation of the trajectory to be machined in hemispherical milling. This compensation is found to be necessary because of the tool deflection due to the cutting forces. In order to remedy to the machining errors, caused by this deflection, a compensation method has been proposed. The latter is inspired from the mirror method, since the compensated position is going to be determined as being the trajectory reflection, deviated onto the mirror. The advantage of this proposed method is that it takes into account the three deflections dx, dy and dz, respectively to the directions X, Y and Z. After that, two-parallel machinings, separated by a groove and achieved absolutely in the same conditions and with the same tool, are carried out, on the same complex part. The first machining is with compensation, but the second is without compensation. The coordinates of the two obtained surfaces are recorded by a 3D measuring machine. The comparison of the two-surfaces shows the presence of an important correction of the tool trajectory, and reveals a similarity between the part obtained by simulation and the one conceived in CAM

An Experimental Investigation of Hot Machining with Induction to Improve Ti-5553 Machinability

The manufacturing of aeronautic parts with high mechanical properties requires the use of high performance materials. That’s why; new materials are used for landing gears such as the titanium alloy Ti-5553. The machining of this material leads to high cutting forces and temperatures, and poor machinability which requires the use of low cutting conditions. In order to increase the productivity rate, one solution could be to raise the workpiece initial temperature. Assisted hot machining consists in heating the workpiece material before the material removal takes place, in order to weaken the material mechanical properties, and thus reducing at least the cutting forces. First, a bibliography review has been done in order to determine all heating instruments used and the thermal alleviation that exists on conventional materials. An induction assisted hot machining was chosen and a system capable to maintain a constant temperature into the workpiece during machining (turning) was designed. Trails permit to identify the variation of cutting forces according to the initial temperature of the workpiece, with fixed cutting conditions according to the TMP (Tool-Material-Pair) methodology at ambient temperature. Tool life and deterioration mode are identified notably. The results analysis shows a low reduction of specific cutting forces for a temperature area compatible with industrial process. The reduction is more important at elevated temperature. However, it has consequences on quality of the workpiece surface and tool wear

Identification of influent factors on surface integrity in nickel-base superalloy drilling

For the critical rotating components in aeronautical industry, the metallurgical quality achieved after machining conditions could determine their mechanical behaviour in fatigue. To guarantee this quality, the tools, materials and cutting conditions are frozen during the validation process by a cutup part following by an acceptable surface integrity. Even with the fixed parameters, perturbations can occur during the process and may have a direct impact over the metallurgical quality through the apparition of anomalies, which could reduce the calculated fatigue life. The aim of this study is to define a Process Monitoring technique able to detect the thickness affected by the machining taking into account the flank wear effect

Analytical and experimental study of feed rate in high-speed milling

In the context of high-speed milling (HSM), during the machining process dynamic machine response has to be identified. To achieve this, we have to calculate the feed rate evolution in linear and circular interpolation according to dynamic performance of machine. In addition to that, actual trajectory for transition passages between two interpolations must be estimated with take into account of specific machining tolerances. This article proposes a model of machine tool behavior for a tool path with linear and circular interpolations and machining cycle time prediction. The method involves subdividing the trajectories into elementary geometries according to the type of interpolation (circular or linear). At points where different trajectories meet, there is often a discontinuity in curvature or in tangency, which decreases the feed rate. At the points of discontinuity in tangency, a fillet radius is inserted. In this article, the influence of the geometry for elementary trajectories was determined. Then, the value of the fillet radius between linear and circular contours in different combinations was modeled. An industrial application was carried out in order to validate models and to determine the influence of feed rate evolution on the machining cycle time

The relationship between the cutting speed, tool wear, and chip formation during Ti-5553 dry cutting

Over the past several years, titanium alloys have been increasingly used in aeronautics. However, they are considered to have poor machinability. The Ti-5553 near-beta titanium alloy is used in aeronautics to replace Ti-64 and for the production of structural parts, such as landing gears. Due to the low thermal properties and the high mechanical properties presented in this work, this alloy is considered difficult to machine. This work is devoted to understanding the relationship between the chip formation, the cutting process, and the tool wear. The first section studies the evolution of the tool wear. The tests show that tool wear occurs in three steps mainly due to the cutting process and the chip formation. To clarify these points, a section is dedicated to the chip formation and cutting processes. An analytical model is also used to quantify stresses, temperatures, and friction inside the workpiece material and at the tool/chip interface. Chip formation is commonly studied using a tool without wear, which can affect the cutting tool geometry. To verify chip formation and the cutting process during machining, a section describes the chip formation and the cutting processes using worn tools

A DH-parameter based condition for 3R orthogonal manipulators to have 4 distinct inverse kinematic solutions

International audiencePositioning 3R manipulators may have two or four inverse kinematic solutions (IKS). This paper derives a necessary and sufficient condition for 3R positioning manipulators with orthogonal joint axes to have four distinct IKS. We show that the transition between manipulators with 2 and 4 IKS is defined by the set of manipulators with a quadruple root of their inverse kinematics. The resulting condition is explicit and states that the last link length of the manipulator must be greater than a quantity that depends on three of its remaining DH-parameters. This result is of interest for the design of new manipulators