Experimental Investigation of End Milling of Titanium Alloys with Polycrystalline Diamond Tools

Wencheng Pan, Adam Kamaruddin, Songlin Ding, John Mo

Research output: Contribution to journalArticle

15 Citations (Scopus)

Abstract

The low thermal conductivity and high chemical reactivity of titanium alloys result in a short tool life in the milling process. This article investigates the performance of polycrystalline diamond tools in the end milling of titanium alloys (Ti6Al4V) by using small customized cutting tools. The relationship between cutting force and cutting parameters was analysed; tool life, tool wear, and causes that lead to tool failure were discussed. To analyse tool wear and cutting temperatures, residual chemical components on the cutting tool were examined with X-ray diffraction method, while surface integrity of cutting tools was inspected based on the images taken by the scanning electrical microscope. Finite element analysis models were developed to simulate the initiation of cracks under different loading cycles. Through cutting experiments, it was found that brittle chipping and fatigue were the two major modes of failure, and feed rate was the dominant factor that causes large cutting forces.
Original languageEnglish
Pages (from-to)832-844
Number of pages13
JournalProceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
Volume228
Issue number8
Early online date12 Feb 2014
DOIs
Publication statusPublished - 1 Aug 2014
Externally publishedYes

Fingerprint

Titanium alloys
Diamonds
Cutting tools
Wear of materials
Chemical reactivity
Thermal conductivity
Microscopes
Fatigue of materials
Cracks
Scanning
Finite element method
X ray diffraction
Experiments
Temperature

Cite this

@article{a582cda2e5f64794b6ead038d36f02a5,
title = "Experimental Investigation of End Milling of Titanium Alloys with Polycrystalline Diamond Tools",
abstract = "The low thermal conductivity and high chemical reactivity of titanium alloys result in a short tool life in the milling process. This article investigates the performance of polycrystalline diamond tools in the end milling of titanium alloys (Ti6Al4V) by using small customized cutting tools. The relationship between cutting force and cutting parameters was analysed; tool life, tool wear, and causes that lead to tool failure were discussed. To analyse tool wear and cutting temperatures, residual chemical components on the cutting tool were examined with X-ray diffraction method, while surface integrity of cutting tools was inspected based on the images taken by the scanning electrical microscope. Finite element analysis models were developed to simulate the initiation of cracks under different loading cycles. Through cutting experiments, it was found that brittle chipping and fatigue were the two major modes of failure, and feed rate was the dominant factor that causes large cutting forces.",
keywords = "Titanium alloys,, PCD, Milling, Cutting Force, tool fractograph, tool life",
author = "Wencheng Pan and Adam Kamaruddin and Songlin Ding and John Mo",
year = "2014",
month = "8",
day = "1",
doi = "10.1177/0954405413514399",
language = "English",
volume = "228",
pages = "832--844",
journal = "Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture",
issn = "0954-4054",
publisher = "SAGE Publications Inc.",
number = "8",

}

Experimental Investigation of End Milling of Titanium Alloys with Polycrystalline Diamond Tools. / Pan, Wencheng; Kamaruddin, Adam; Ding, Songlin; Mo, John.

In: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 228, No. 8, 01.08.2014, p. 832-844.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Experimental Investigation of End Milling of Titanium Alloys with Polycrystalline Diamond Tools

AU - Pan, Wencheng

AU - Kamaruddin, Adam

AU - Ding, Songlin

AU - Mo, John

PY - 2014/8/1

Y1 - 2014/8/1

N2 - The low thermal conductivity and high chemical reactivity of titanium alloys result in a short tool life in the milling process. This article investigates the performance of polycrystalline diamond tools in the end milling of titanium alloys (Ti6Al4V) by using small customized cutting tools. The relationship between cutting force and cutting parameters was analysed; tool life, tool wear, and causes that lead to tool failure were discussed. To analyse tool wear and cutting temperatures, residual chemical components on the cutting tool were examined with X-ray diffraction method, while surface integrity of cutting tools was inspected based on the images taken by the scanning electrical microscope. Finite element analysis models were developed to simulate the initiation of cracks under different loading cycles. Through cutting experiments, it was found that brittle chipping and fatigue were the two major modes of failure, and feed rate was the dominant factor that causes large cutting forces.

AB - The low thermal conductivity and high chemical reactivity of titanium alloys result in a short tool life in the milling process. This article investigates the performance of polycrystalline diamond tools in the end milling of titanium alloys (Ti6Al4V) by using small customized cutting tools. The relationship between cutting force and cutting parameters was analysed; tool life, tool wear, and causes that lead to tool failure were discussed. To analyse tool wear and cutting temperatures, residual chemical components on the cutting tool were examined with X-ray diffraction method, while surface integrity of cutting tools was inspected based on the images taken by the scanning electrical microscope. Finite element analysis models were developed to simulate the initiation of cracks under different loading cycles. Through cutting experiments, it was found that brittle chipping and fatigue were the two major modes of failure, and feed rate was the dominant factor that causes large cutting forces.

KW - Titanium alloys,

KW - PCD

KW - Milling

KW - Cutting Force

KW - tool fractograph

KW - tool life

U2 - 10.1177/0954405413514399

DO - 10.1177/0954405413514399

M3 - Article

VL - 228

SP - 832

EP - 844

JO - Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

JF - Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

SN - 0954-4054

IS - 8

ER -