Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 2: Effect of tool failure modes

Author:

Sun Shoujin12,Brandt Milan12,Dargusch Matthew S23

Affiliation:

1. School of Aerospace, Mechanical and Manufacturing Engineering, RMIT University, Melbourne, VIC, Australia

2. Defence Materials Technology Centre, Hawthorn, VIC, Australia

3. Centre for Advanced Materials Processing and Manufacture, School of Mechanical & Mining Engineering, The University of Queensland, Brisbane, QLD, Australia

Abstract

Variation in the geometric and surface features of segmented chips with an increase in the volume of material removed and tool wear has been investigated at cutting speeds of 150 and 220 m/min at which the cutting tools fail due to gradual flank wear and plastic deformation of the cutting edge, respectively. Among the investigated geometric variables of the segmented chips, slipping angle, undeformed surface length, segment spacing, degree of segmentation and chip width showed the different variation trends with an increase in the volume of material removed or flank wear width, and achieved different values when tool failed at different cutting speeds. However, the chip geometric ratio showed a similar variation trend with an increase in the volume of material removed and flank wear width, and achieved the similar value at the end of tool lives at cutting speeds of both 150 and 220 m/min regardless of the different tool failure modes. Plastic deformation of the tool cutting edge results in severe damage on the machined surface of the chip and significant compression deformation on the undeformed surface of the chip.

Publisher

SAGE Publications

Subject

Industrial and Manufacturing Engineering,Mechanical Engineering

Cited by 17 articles. 订阅此论文施引文献 订阅此论文施引文献,注册后可以免费订阅5篇论文的施引文献,订阅后可以查看论文全部施引文献

1. Tool wear evolution and chip formation of the Ti-6Al-4V end milling under cryogenic cooling and minimum quantity lubrication conditions;The International Journal of Advanced Manufacturing Technology;2023-11-30

2. Application of machine vision for tool condition monitoring and tool performance optimization–a review;The International Journal of Advanced Manufacturing Technology;2022-08

3. Sustainability Evaluation of Machining Ti6Al4V with Graphene Inclusion;International Journal of Automotive and Mechanical Engineering;2022-06-28

4. Machinability of Ti6Al4V as influenced by cutting velocity, tool feed and cutting depth;Materials Today: Proceedings;2022

5. Analytical modeling of tool failure boundary map in milling titanium alloy;Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture;2021-08-30

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