The performance of PCD tools in high-speed milling of Ti6Al4V

Tool performance of conventional tools is poor and a major constraint when used in milling titanium alloys at elevated cutting speeds. At these high cutting speeds, the chemical and mechanical properties of Ti6Al4V cause complex wear mechanisms. In this paper, a fine-grain polycrystalline diamond (PCD) end mill tool was tested, and its wear behavior was studied. The performance of the PCD tool has been investigated in terms of tool life, cutting forces, and surface roughness. The PCD tool yielded longer tool life than a coated carbide tool at cutting speeds above 100 m/min. A slower wear progression was found with an increase in cutting speeds, whereas the norm is an exponential increase in tool wear at elevated speeds. Observations based on scanning electron microscope (SEM) and energy dispersive spectroscopy (EDAX) analysis suggest that adhesion of the workpiece is the wear main type, after which degradation of the tools accelerates probable due to the combined effect of high temperature degradation coupled with abrasion.

[1]  R. Komanduri,et al.  On thermoplastic shear instability in the machining of a titanium alloy (Ti-6Al-4V) , 2002 .

[2]  Joseph A. Arsecularatne,et al.  Wear and tool life of tungsten carbide, PCBN and PCD cutting tools , 2006 .

[3]  Eberhard Abele,et al.  Analysis of cutting force during milling with regards to the dependency on the penetration angle , 2009, Prod. Eng..

[4]  M. Donachie.  Titanium: A Technical Guide , 1988 .

[5]  Yongsheng Su,et al.  An experimental investigation of effects of cooling/lubrication conditions on tool wear in high-speed end milling of Ti-6Al-4V , 2006 .

[6]  Mahmudur Rahman,et al.  Tool wear characteristics of binderless CBN tools used in high-speed milling of titanium alloys , 2005 .

[7]  A. Jawaid,et al.  The effect of machining on surface integrity of titanium alloy Ti–6% Al–4% V , 2005 .

[8]  M. Kikuchi.  The use of cutting temperature to evaluate the machinability of titanium alloys. , 2009, Acta biomaterialia.

[9]  A. F. Ismail,et al.  Effectiveness of uncoated WC–Co and PCD inserts in end milling of titanium alloy—Ti–6Al–4V , 2007 .

[10]  Elso Kuljanić,et al.  Milling Titanium Compressor Blades with PCD Cutter , 1998 .

[11]  E. Ezugwu,et al.  An overview of the machinability of aeroengine alloys , 2003 .

[12]  Turning TiAl6V4 with PCD , 1993 .

[13]  Y. Honnorat.  Issues and breakthrough in the manufacture of turboengine titanium parts , 1996 .

[14]  Schaftfräsen von Titanlegierungen mit hohen Schnittgeschwindigkeiten. I : Schruppen , 1991 .

[15]  P. Dearnley,et al.  Evaluation of principal wear mechanisms of cemented carbides and ceramics used for machining titanium alloy IMI 318 , 1986 .

[16]  Rosemar Batista da Silva,et al.  Surface integrity of finished turned Ti–6Al–4V alloy with PCD tools using conventional and high pressure coolant supplies , 2007 .

[17]  Gérard Poulachon,et al.  Wear Mechanisms of New Tool Materials for Ti-6AI-4V High Performance Machining , 2003 .

[18]  Z. G. Wang,et al.  A Review on High-Speed Machining of Titanium Alloys ∗ , 2006 .

[19]  J. Isern,et al.  Technical Guide , 2020, Definitions.

[20]  R. Krishnamurthy,et al.  The performance of CBN tools in the machining of titanium alloys , 2000 .

[21]  Shraga Shoval,et al.  Fast evaluation of cutting forces in milling, applying no approximate models , 1997 .