Influence of cutting speed on cutting force, flank temperature, and tool wear in end milling of Ti-6Al-4V alloy

Tool wear is one of the most important problems in cutting titanium alloys due to the high-cutting temperature and strong adhesion. Recently, the high-speed machining process has become a topic of great interest for titanium alloys, not only because it increases material removal rates, but also beca...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2014-02, Vol.70 (9-12), p.1835-1845
Main Authors: Hou, Junzhan, Zhou, Wei, Duan, Hongjian, Yang, Guang, Xu, Hongwei, Zhao, Ning
Format: Article
Language:English
Subjects:
Abrasion
Adhesive strength
CAE) and Design
Carbide tools
Coating
Computer-Aided Engineering (CAD
Cutting force
Cutting speed
Cutting wear
End milling cutters
Engineering
High speed machining
Industrial and Production Engineering
Inserts
Mechanical Engineering
Media Management
Original Article
Physical vapor deposition
Production planning
Titanium alloys
Titanium base alloys
Tool wear
Workpieces
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Summary:Tool wear is one of the most important problems in cutting titanium alloys due to the high-cutting temperature and strong adhesion. Recently, the high-speed machining process has become a topic of great interest for titanium alloys, not only because it increases material removal rates, but also because it can positively influence the properties of finished workpiece. However, the process may result in the increase of cutting force and cutting temperature which will accelerate tool wear. In this paper, end milling experiments of Ti-6Al-4V alloy were conducted at high speeds using both uncoated and coated carbide tools. The obtained results show that the cutting force increases significantly at higher cutting speed whether the cutter is uncoated carbide or TiN/TiAlN physical vapor deposition (PVD)-coated carbide. For uncoated carbide tools, the mean flank temperature is almost constant at higher cutting speed, and no obvious abrasion wear or fatigue can be observed. However, for TiN/TiAlN PVD-coated carbide tools, the mean flank temperature always increases as the increase of cutting speed, and serious abrasion wear can be observed. In conclusion, the cutting performance of uncoated inserts is relatively better than TiN/TiAlN PVD-coated inserts at a higher cutting speed.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-013-5433-8