Abstract
The low thermal conductivity and high chemical affinity of Ti6Al4V make it extremely difficult to machine. The thermal characteristics in milling Ti6Al4V with polycrystalline diamond (PCD) tools were studied in the paper. A predictive model was developed and validated to investigate the relationship between average cutting temperature and machining parameters. X-ray diffraction (XRD) method was applied to examine residual chemical components on the PCD tools. Evidences of material diffusion and chemical reaction on the PCD tool showed that some region of the cutter suffered from higher than detected temperature. Based on SEM photos of serrated chips, serration frequency was investigated. Results from chip morphology illustrated that serration frequency changed on each single chip.
Similar content being viewed by others
References
Manouchehr V, Fredrik S, Mathias A, Jan-Eric S (2013) A method for identification of geometrical tool changes during machining of titanium alloy Ti6Al4V. Int J Adv Manuf Technol 67:339–348
Rosemar B, Alisson DS, Machado R, Emmanuel OE, John B, Wisley FS (2013) Tool life and wear mechanisms in high speed machining of Ti–6Al–4V alloy with PCD tools under various coolant pressures. J Mater Process Technol 213:1459–1464
Mohd Hadzley AB, Izamshah R, Sarah AS, Nurul Fatin M (2013) Finite element model of machining with high pressure coolant for Ti-6Al-4V alloy. Procedia Eng 53:624–631
Emmanuel OE, John B, Rosemar B, Da Silva O, Akir C (2007) Surface quality of finished turned Ti–6Al–4V alloy with PCD tools using conventional and high pressure coolant supplies. Int J Mach Tools Manuf 47:884–891
Nurul Amin AKM, Ahmad FI, Nor Khairusshim MK (2007) Effectiveness of uncoated WC–Co and PCD inserts in end milling of titanium alloy—Ti–6Al–4V. J Mater Process Technol 192–193:147–158
Kuljanic, Fioretti M, Beltrame L, Rosa P, Miani F (1998) Milling titanium compressor blades with PCD cutter. Ann ClRP 47(1):61–64
Anhai L, Jun Z, Dong W, Jiabang Z, Youngwang D (2013) Failure mechanisms of a PCD tool in high-speed face milling of Ti6Al4V alloy. Int J Adv Manuf Technol 67:1959–1966
Gert AO, Guven A, Nico T (2011) The performance of PCD tools in high-speed milling of Ti6Al4V. Int J Adv Manuf Technol 52:929–935
Le Coz G, Marinescu M, Devillez A, Dudzinski D, Velnom L (2012) Measuring temperature of rotating cutting tools: application to MQL drilling and dry milling of aerospace alloys. Appl Therm Eng 36:434–441
Masahiko S, Takashi U, Hisataka T (2007) An experimental technique for the measurement of temperature on CBN tool face in end milling. Int J Mach Tools Manuf 47:2071–2076
Pittalà GM, Monno M (2011) A new approach to the prediction of temperature of the workpiece of face milling operations of Ti-6Al-4V. Appl Therm Eng 31:173–180
Ugarte A, M’Saoubi R, Garay A, Arrazola PJ (2012) Machining behaviour of Ti-6Al-4V and Ti-5553 alloys in interrupted cutting with PVD coated cemented carbide. Procedia CIRP 1:202–207
Abhang LB, Hameedullah M (2010) Chip-tool interface temperature prediction model for turning process. Int J Eng Sci Technol 2(4):382–393
Xuance Z, Qingshun B, Kai Y, Zhi L (2010) Relationship between cutting temperature and cutting parameters of micro-milling. World Acad Sci Eng Technol 46
Lin S, Peng FY, Wen J, Liu YZ, Yan R (2013) An investigation of workpiece temperature variation in end milling considering flank rubbing effect. Int J Mach Tools Manuf 73:71–86
Cui XB, Zhao J, Pei ZQ (2012) Analysis of transient average tool temperatures in face milling. Int Commun Heat Mass Transfer 39:786–791
Machado AR, Wallbank J (1990) Machining of titanium and its alloys—a review. Proc Inst Mech Eng B J Eng Manuf 53:204
Deng JX, Li YS, Song WL (2008) Diffusion wear in dry cutting of Ti–6Al–4V withWC/Co carbide tools. Wear 265:1776–1783
König W, Neises N (1993) Turning TiAl6V4 with PCD. Ind Diam Rev 53(1):85–88
Puerta JD, Velásquez Bolle B, Chevrier P, Geandier G, Tidu A (2007) Metallurgical study on chips obtained by high speed machining of a Ti–6 wt.%Al–4 wt.%V alloy. Mater Sci Eng A 452–453:469–474
Miguélez MH, Soldani X, Molinari A (2013) Analysis of adiabatic shear banding in orthogonal cutting of Ti alloy. Int J Mech Sci 75:212–222
Sima M, Ozel T (2010) Modified material constitutive models for serrated chip formation simulations and experimental validation in machining of titanium alloy Ti–6Al–4V. Int J Mach Tools Manuf 50:943–960
Molinari A, Soldani X, Miguélez MH (2013) Adiabatic shear banding and scaling laws in chip formation with application to cutting of Ti–6Al–4V. J Mech Phys Solids 61:2331–2359
Baker M (2003) The influence of plastic properties on chip formation. Comput Mater Sci 28:556–562
American Society for Testing and Materials (ASTM), “Standard Specification for Titanium and Titanium Alloy Strip, Sheet, and Plate”, ASTM B265-99
Costan A, Dima A, Ioniţă I, Forna N, Perju M, Agop M (2011) Thermal properties of a Ti-6Al-4V alloy used as dental implant material. Optoelectron Adv Mater Rapid Commun 5:1
Collins JL, Cook MW, Ninnis T (2011) New developments in ultrahard machining of wood and non-metals. Ind Diam Rev 61(588):49–62
Abukhshim NA, Mativenga PT, Sheikh MA (2006) Heat generation and temperature prediction in metal cutting: a review and implications for high speed machining. Int J Mach Tools Manuf 46:782–800
Anayet UPM, Nurul Amin AKM, Faris WF (2009) Prediction of tangential cutting force in end milling of medium carbon steel by coupling design of experiment and response surface methodology. J Mech Eng 40:2
Umbrello D (2008) Finite element simulation of conventional and high speed machining of Ti6Al4V alloy. J Mater Process Technol 196:79–87
Balkrishna R, Chinmaya RD, Yung CS (2011) An experimental and numerical study on the face milling of Ti–6Al–4V alloy: tool performance and surface integrity. J Mater Process Technol 211:294–304
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Pan, W., Ding, S. & Mo, J. Thermal characteristics in milling Ti6Al4V with polycrystalline diamond tools. Int J Adv Manuf Technol 75, 1077–1087 (2014). https://doi.org/10.1007/s00170-014-6094-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-6094-y