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Thermal-Assisted Machining of Titanium Alloys

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Advanced Manufacturing Technologies

Part of the book series: Materials Forming, Machining and Tribology ((MFMT))

Abstract

Titanium alloys are used in a variety of engineering applications, especially in automotive, aerospace and nuclear fields due to their high strength and excellent corrosion resistance. Nevertheless, titanium alloys have extreme mechanical properties making them very difficult to machine with low thermal conductivity and high chemical reactivity at high temperature. Hence, titanium alloys are required to machine at low cutting speed and feed rate but that increases the cost of production of the components made by these alloys at large. Thermal-assisted machining (TAM) is an effective approach for conventional machining whereby titanium workpiece is locally softened before/during machining with external heating. Localized reduction in workpiece hardness facilitates higher material removal rate (MRR) and extended cutting tool life whilst resulting in better surface finish. This chapter compares and analyzes the merits of different heating techniques for machining of titanium alloys. The techniques under consideration are heating by laser beam, plasma torch heating and heating with the use of induction coil. The laser beam and plasma torch tend to produce more intense localized heating compare to that by induction coil. Moreover, the laser technique offers very controllable process heating compared to other two techniques. Laser-assisted machining (LAM) also largely reduces cutting forces leading to better surface finish. Thus, laser-assisted technique is recognized to be more cost-effective and productive for improving machinability of titanium alloys than rest of the heating techniques.

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Abbreviations

a e :

Radial depth of cut (mm)

a p :

Axial depth of cut (mm)

D :

Tool or workpiece diameter (mm)

f z :

Feed per tooth (mm)

f r :

Feed per revolution (mm)

F :

Machine linear feed, similar to the translational velocity of the plasma torch (N)

F v :

Thrust force (N)

F t :

Tangential force (N)

I :

Plasma intensity (A)

L :

Lens-workpiece distance on chamfer surface (mm)

L 1 :

Tool-laser beam distance on the surface of workpiece (mm)

\(P_{{CO_{2} }}\) :

Power of CO2 laser (kW)

RT :

Room temperature (°C)

S :

Rotary speed of the spindle (r.p.m)

T mr :

Material removal temperature

T o :

Initial workpiece bulk temperature (°C)

T s :

Surface temperature (°C)

V c :

Cutting speed (m/min)

z :

Number of teeth of the milling tool

α :

Angle between workpiece axis and beam axis (degree)

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  1. Department of Mechanical Engineering, Curtin University, Bentley, Australia

    O. A. Shams, A. Pramanik & T. T. Chandratilleke

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  1. O. A. Shams
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    Kapil Gupta

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Shams, O.A., Pramanik, A., Chandratilleke, T.T. (2017). Thermal-Assisted Machining of Titanium Alloys. In: Gupta, K. (eds) Advanced Manufacturing Technologies. Materials Forming, Machining and Tribology. Springer, Cham. https://doi.org/10.1007/978-3-319-56099-1_3

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