An investigation into cutting fluid additives performance during machining processing of Ti-6Al-4V
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ORIGINAL ARTICLE
An investigation into cutting fluid additives performance during machining processing of Ti-6Al-4V Junhui Ma 1 & Javad Mohammadi 1 & Yan Zhou 2 & Jeff Larsh 2 & Kris Januszkiewicz 2 & Robert Evans 2 & Yixing Zhao 2 & Olufisayo A. Gali 1 & Reza A. Riahi 1 Received: 12 August 2020 / Accepted: 19 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The application of cutting fluids to the machining of titanium alloys has received increasing interest due to the severe tribological conditions occurring during this process. Cutting fluids are applied during the machining process to reduce tool wear, friction, and heat generation. This study was carried out to investigate the effect of polymer-based additives and phosphorus-based additives on the cutting fluid performance during the drilling of a titanium alloy, Ti-6Al-4V, under a constant metal removal rate (MRR) of 4.2 mm3/s. The tool wear and specific cutting energy (SCE) were evaluated to assess the performance of the additives in a cutting fluid. The performance of the additives was dependent on the drilling conditions. At the lower limit of the drilling conditions tested (500 RPM under 4.2 mm3/s MRR), the cutting fluid with high phosphorus concentration was able to achieve better lubricity. While at the higher limit drilling conditions (700–2500 RPM under 4.2 mm3/s MRR), the cutting fluid with primarily polymer-based additives was more effective at providing improved drilling performance. The improvement in the drilling performance of the cutting fluids was related to the formation of boundary layers associated with additives employed. An optimum range (providing the lowest SCE value) within the tested drilling conditions was noted for the cutting fluids. Keywords Titanium alloy . Ti-6Al-4V . Cutting fluids . Drilling . Additives . Specific cutting energy (SCE)
1 Introduction Lightweight metals such as titanium alloys continue to receive increasing interests in the aerospace and general engineering industries. This is due to their high specific strength, fracture resistance, excellent corrosion resistance, and their hightemperature properties [1–3]. As lightweight materials, the machining of titanium alloys has become an essential operation in the aerospace industry to aid fuel consumption reduction [4]. However, the difficulties in machining titanium alloys result in high costs attached to the use of these alloys [5]. This hard-to-machine property has been related to titanium alloys’ high chemical reactivity and low thermal conductivity
* Junhui Ma [email protected] 1
Department of Mechanical, Automotive & Materials Engineering, University of Windsor, Windsor, Ontario N9B 3P4, Canada
2
Research & Development, Quaker Houghton, Eagleville, PA 19403, USA
which leads to the adhesion of titanium to the tool surface as well as high temperatures within the cutting zone. The machinability of metals is typically determined by such parameters as tool life, cutting force, chip formation, and surface integrity. The ideal v
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