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Milling of Ti-6Al-4V alloy using hybrid geometry tooling

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Abstract

The novel tool geometry has been fabricated by a tool manufacturer which is termed as “Z Geometry” having a combination of positive and negative rake angles on a single insert. The term Z-geometry was given to the insert due to its appearance like alphabet “Z” character in its side view. With this special geometry, productivity of Ti-6Al-4V alloy can be increased at elevated feed rate. With this Z geometry, a special type of wiper insert having a flat flank face for robust rubbing action was provided to reduce the surface roughness. The combination of inserts, i.e., Z-geometry and wiper insert, is termed as hybrid geometry. This paper involves the evaluation of tool life, material removed, temperature of the machining zone, and surface roughness during the dry milling of Ti-6Al-4V alloy using hybrid geometry tooling at higher feed rates compared to the literature. Feed rate at four levels (0.30, 0.60, 0.90, 1.20 mm/rev) and depth of cut at two levels (0.50, 0.75 mm) were employed while number of wiper inserts were varied from one to two. Maximum material of 108 cm3 was removed in 20 min at a feed rate of 0.60 mm/rev and 0.50-mm depth of cut. Variation in surface roughness was within 0.20 to 0.50 μm over the course of experimentation irrespective of the variables and tool condition.

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Authors and Affiliations

  1. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, Pakistan

    Sana Ehsan, Sarmad Ali Khan, Mohammad Pervez Mughal, Muhammad Qaiser Saleem & Nadeem Ahmad Mufti

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  1. Sana Ehsan
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Ehsan, S., Khan, S.A., Mughal, M.P. et al. Milling of Ti-6Al-4V alloy using hybrid geometry tooling. Int J Adv Manuf Technol 105, 5045–5059 (2019). https://doi.org/10.1007/s00170-019-04613-1

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