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Crater wear prediction in turning Ti6Al4V considering cutting temperature effect

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Abstract

Tool wear has great impacts on tool life and cutting parameter selection in the machining process. As ceramic inserts are widely employed in efficient machining, it is of great significance to predict accurately the wear of ceramic tools. Crater wear is one of the most significant tool wear modes when turning difficult-to-cut materials at high speeds. The purpose of this research is to demonstrate the forming and influence mechanisms of crater wear in Ti6Al4V turning with ceramic inserts while considering cutting temperature at the tool-chip interface. An effort is made to describe quantitatively the appearance of crater wear from the perspective of temperature distribution based on crater wear experiments under various cutting conditions. In order to obtain the cutting temperature distribution efficiently, an analytical temperature prediction model is used in this paper. Then, a prediction model for crater wear depth and width considering the influence of the maximum temperature is developed. The maximum crater wear depth and width models are validated by a series of cutting experiments, and the outcomes prove that the proposed models are practical. Additionally, the influence of various cutting parameters on crater wear is discussed. The cutting speed has the greatest impact on crater wear, followed by the feed rate. Furthermore, this research can be used to improve cutting parameters for controlling crater wear.

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Availability of data and material

The data in this study is obtained or measured through the corresponding experiments, and the materials have been given in this paper. They can be used as a reference for the related researchers.

Abbreviations

K T :

The maximum depth of crater wear

K B :

The maximum width of crater wear

T max :

The maximum temperature value at the tool-chip interface

V c :

Cutting speed

F t :

Feed rate

a p :

Cutting depth

DMZ:

Dead metal zone

PDZ:

The primary deformation zone

SDZ:

The secondary deformation zone

q pr, q se, q d :

Intensity of the heat source in the primary deformation zone, secondary deformation zone and dead metal zone, respectively

A 0,  B 0,  C 0,  n 0,  m 0 :

Material constants

T m,  T r :

Melting temperature and room temperature

σ :

Shear strain

dσ :

Shear strain rate

dσ 0 :

Reference shear strain rate

V s :

Shear velocity

V ch :

Chip flow velocity

V m :

DMZ velocity

τ s,  τ m,  τ c :

Local shear flow stresses

θ :

Slip-line angle

γ :

Rake angle

ϕ :

Shear angle

ϕ s :

Immersion angle

η r :

Chip flow angle on the rake plane

ξ 1,  ξ 2 :

Friction factor angle

θ c :

Addition of chamfer angle

α 0 :

Initial rake angle

α n :

Local rake angle

l m :

Side length of the dead metal zone

l c :

Side length of the secondary heat source

l s :

Side length of the primary heat source

w :

Cutting width

B tool :

Dynamic heat distribution coefficient of the heat sources on the tool side

B chip :

Dynamic heat distribution coefficient of the heat sources on the chip side

B c,  B t,  ΔB,  C 1,  m,  k :

Adjusting factors

S 0,  K 0 :

Constant coefficients

α w,  λ w :

Thermal diffusivity and conductivity of workpiece

α t,  λ t :

Thermal diffusivity and conductivity of tool

α :

Angle of crater wear

R :

Radius of crater wear

S :

Volume of crater wear

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Funding

This work was financially supported by the Guangdong Major Project of Basic and Applied Basic Research (2021B0301030001), the National Natural Science Foundation of China (52175482), the Hubei Province Natural Science Foundation of China (2021CFB304) and the State Key Laboratory of Digital Manufacturing Equipment and Technology (DMETKF2021005, DMETKF2021022).

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Authors and Affiliations

  1. Hubei Digital Manufacturing Key Laboratory, School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Kejia Zhuang, Ming Li, Cheng Hu, Jian Weng, Zhongmei Gao & Chaoqun Wu

  2. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Kejia Zhuang & Zhongmei Gao

  3. Xiamen Golden Egret Special Alloy Corporation Limited, Xiamen, 361000, China

    Fengtian Lin

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  1. Kejia Zhuang
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Correspondence to Zhongmei Gao.

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Zhuang, K., Li, M., Lin, F. et al. Crater wear prediction in turning Ti6Al4V considering cutting temperature effect. Int J Adv Manuf Technol 121, 6763–6781 (2022). https://doi.org/10.1007/s00170-022-09773-1

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