An Experimental and Numerical Study on Orthogonal Machining of Ti–6Al–4V Alloy
-
Vijayan Krishnaraj
Abstract
In this work experimental and numerical result of high speed orthogonal machining of Ti-6AL-4V titanium alloy is presented. High speed orthogonal turning is carried in a lathe using uncoated carbide inserts under dry cutting conditions. Experimental study is carried out by focusing on the measurement of cutting force and cutting temperature. The experimentation is supplemented by simulations from 2D finite element model (FEM) using Third Wave AdvantEdge software. The measured cutting forces and temperature are compared with FEA results. The major factors affecting the machinability of titanium alloy such as spindle speed, feed and cutting tool rake angles are investigated. Numerical results agree with the experimental results at higher speeds and feed levels. These results can be used for further study in high speed turning of titanium alloys.
References
1. Myers JR, Bomberger HB, Froes FH. Corrosion behaviour and use of titanium and its alloys. J Met 1984;36(10):50–60.Search in Google Scholar
2. Van Kann H. Titanium and titanium alloys, vol. 1. NY: Plenum Press, 1982:229–34.Search in Google Scholar
3. Che-Haron CH, Jawaid A. The effect of machining on surface integrity of titanium alloy Ti–6% Al–4% V. J Mater Process Technol 2005;166:188–92.10.1016/j.jmatprotec.2004.08.012Search in Google Scholar
4. Schulz H, Moriwaki T. High-speed machining. Ann CIRP 1992;41(2):637–45.10.1007/978-3-642-55776-7_7Search in Google Scholar
5. Ashley S. High-speed machining goes mainstream. Mech Eng 1995;117(5):56–61.Search in Google Scholar
6. Gente A, Hoffmeister HW. Chip formation in machining Ti-6Al-4V at extremely cutting speed. Ann CIRP 2001;50(1):49–52.10.1016/S0007-8506(07)62068-XSearch in Google Scholar
7. Komanduri R, Schroeder TA, Bandhopadhyay DK, Hazra J. Titanium: a model material for analysis of the high-speed machining process, advanced processing methods for titanium. The Metallurgical Society of ASME, 1982:241–56.Search in Google Scholar
8. Hua J, Shivpuri R. Prediction of chip morphology and segmentation during the machining of titanium alloys. J Mater Process Technol 2004;150:124–33.10.1016/j.jmatprotec.2004.01.028Search in Google Scholar
9. President Titanium, 1999. Machining and technical data, Hanson.Search in Google Scholar
10. Chen P. Characteristics of self-propelled rotary tools in machining high-performance materials. Japan Soc Precis Eng 1991;25(4):267–72.Search in Google Scholar
11. Wang ZM, Ezugwu EO, Gupta A. Evaluation of a self-propelled rotary tool in the machining of aerospace materials. Tribol Trans 1998;41(2):289–95.10.1080/10402009808983750Search in Google Scholar
12. Shaw MC. Metal cutting principles. London: Oxford University Press, 2005.Search in Google Scholar
13. Trent EM. Metal cutting. London: Butterworth Heinemann, 2000.10.1016/B978-075067069-2/50007-3Search in Google Scholar
14. Barrow G. A review of experimental and theoretical techniques for assessing cutting temperatures. Ann CIRP 1973;22:203–11.Search in Google Scholar
15. Obikawa T, Usui E. Computational machining of titanium alloy – finite element modeling and a few results. J Manuf Sci Eng 1996;118:208–15.10.1115/1.2831013Search in Google Scholar
16. Yang X, Liu CR. A new stress-based model of friction behavior in machining and its significant impact on residual stresses computed by Finite element method. Int J Mech Sci 2002;44:703–23.10.1016/S0020-7403(02)00008-5Search in Google Scholar
17. Groover MP. Fundamentals of modern manufacturing: materials, processes, and systems. USA: John Wiley & Sons Inc., 2010.Search in Google Scholar
©2016 by De Gruyter
Articles in the same Issue
- Frontmatter
- An Experimental and Numerical Study on Orthogonal Machining of Ti–6Al–4V Alloy
- Formation of Chromium-Containing Molten Salt Phase during Roasting of Chromite Ore with Sodium and Potassium Hydroxides
- Slag Formation – Thermodynamic Aspects and Experimental Observations
- A Slag Management Toolset for Determining Optimal Coal Gasification Temperatures
- A Review on Strategic Positioning of Bottleneck around the Customer Order Decoupling Point and Issues on Production Planning in Supply Chain
- Investigation on Effect of Machining Parameters of End Milling on Surface Finish and Temperature Using Taguchi Technique
- Multi-Objective Optimization of HAZ Characteristics for Submerged Arc Welding of Micro-Alloyed High Strength Pipeline Steel using GRA-PCA Approach
Articles in the same Issue
- Frontmatter
- An Experimental and Numerical Study on Orthogonal Machining of Ti–6Al–4V Alloy
- Formation of Chromium-Containing Molten Salt Phase during Roasting of Chromite Ore with Sodium and Potassium Hydroxides
- Slag Formation – Thermodynamic Aspects and Experimental Observations
- A Slag Management Toolset for Determining Optimal Coal Gasification Temperatures
- A Review on Strategic Positioning of Bottleneck around the Customer Order Decoupling Point and Issues on Production Planning in Supply Chain
- Investigation on Effect of Machining Parameters of End Milling on Surface Finish and Temperature Using Taguchi Technique
- Multi-Objective Optimization of HAZ Characteristics for Submerged Arc Welding of Micro-Alloyed High Strength Pipeline Steel using GRA-PCA Approach
