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Effects of cutting parameters on tool insert wear in end milling of titanium alloy Ti6Al4V

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Abstract

Titanium alloy is a kind of typical hard-to-cut material due to its low thermal conductivity and high strength at elevated temperatures, this contributes to the fast tool wear in the milling of titanium alloys. The influence of cutting conditions on tool wear has been focused on the turning process, and their influence on tool wear in milling process as well as the influence of tool wear on cutting force coefficients has not been investigated comprehensively. To fully understand the tool wear behavior in milling process with inserts, the influence of cutting parameters on tool wear in the milling of titanium alloys Ti6Al4V by using indexable cutters is investigated. The tool wear rate and trends under different feed per tooth, cutting speed, axial depth of cut and radial depth of cut are analyzed. The results show that the feed rate per tooth and the radial depth of cut have a large influence on tool wear in milling Ti6Al4V with coated insert. To reduce tool wear, cutting parameters for coated inserts under experimental cutting conditions are set as: feed rate per tooth less than 0.07 mm, radial depth of cut less than 1.0 mm, and cutting speed sets between 60 and 150 m/min. Investigation on the relationship between tool wear and cutting force coefficients shows that tangential edge constant increases with tool wear and cutter edge chipping can lead to a great variety of tangential cutting force coefficient. The proposed research provides the basic data for evaluating the machinability of milling Ti6Al4V alloy with coated inserts, and the recommend cutting parameters can be immediately applied in practical production.

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Authors and Affiliations

  1. Key Laboratory of Contemporary Design and Integrated Manufacturing Technology of Ministry of Education, Northwestern Polytechnical University, Xi’an, 710072, China

    Ming Luo, Jing Wang, Baohai Wu & Dinghua Zhang

Authors
  1. Ming Luo
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  2. Jing Wang
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  3. Baohai Wu
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  4. Dinghua Zhang
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Corresponding author

Correspondence to Ming Luo.

Additional information

Supported by National Basic Research Program of China (973 Program, Grant No. 2013CB035802), National Natural Science Foundation of China (Grant No. 51575453), Fundamental Research Funds for the Central Universities(Grant No. 3102015JCS05002), and the 111 Project, China (Grant No. B13044)

LUO Ming, born in 1983, is currently a junior research scientist at Key Laboratory of Contemporary Design and Integrated Manufacturing Technology of Ministry of Education, Northwestern Polytechnical University, China. He received his PhD degree from Northwestern Polytechnical University, China, in 2012. His research interests include CAD/CAM, smart machining, machining dynamics and high performance cutting.

WANG Jing, born in 1986, is currently a PhD candidate at Key Laboratory of Contemporary Design and Integrated Manufacturing Technology of Ministry of Education, Northwestern Polytechnical University, China. He received his master degree on advanced manufacturing engineering in Northwestern Polytechnical University, China, in 2014.

WU Baohai, born in 1975, is currently an professor at Key Laboratory of Contemporary Design and Integrated Manufacturing Technology of Ministry of Education, Northwestern Polytechnical University, China. His research interests include CAD/CAM, smart machining, tool wear.

ZHANG Dinghua, born in 1958, is currently a professor at Key Laboratory of Contemporary Design and Integrated Manufacturing Technology of Ministry of Education, Northwestern Polytechnical University, China. His research interests include CAD/CAM, smart machining, mold design and manufacturing, nondestructive testing and cone beam CT technology.

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Luo, M., Wang, J., Wu, B. et al. Effects of cutting parameters on tool insert wear in end milling of titanium alloy Ti6Al4V. Chin. J. Mech. Eng. 30, 53–59 (2017). https://doi.org/10.3901/CJME.2016.0405.045

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  • DOI: https://doi.org/10.3901/CJME.2016.0405.045

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