Investigation on PCD cutting edge geometry for Ti6Al4V high-feed milling
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ORIGINAL ARTICLE
Investigation on PCD cutting edge geometry for Ti6Al4V high-feed milling Anna Carla Araujo1,2,3 · Guillaume Fromentin1 · Patrick Blandenet4 Received: 27 May 2020 / Accepted: 14 September 2020 / Published online: 18 October 2020 © Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Some new research challenges are connected to new high-feed milling tools, developed recently to reduce the cutting time. The main objective of this article is to analyze if PCD tools could be used for high-feed face milling of Ti6Al4V. As its performance depends significantly on cutting edge geometry, different tool geometries were evaluated regarding tool life and cutting forces. Experimental investigations demonstrate that the tool profile, which has a discontinuity on chip flow direction along the cutting edge, presents an intense local tool wear and, consequently, a smaller tool life. The PCD tool having a straight edge has a longer tool life but, contrarily to the carbide tool theory, local wear behavior on the cutting edge is not constant when depth of cut increases. The cutting force magnitude, and its dynamic, affects drastically the tool life of PCD tools in milling and it is a limitation to the increase of the material removal rate. In conclusion, it is possible to use specific PCD tools for milling titanium alloy in high feed with low depth of cut (smaller than 1 mm), which is not economically practicable. Keywords High feed milling · Cutting forces · Tool life · Titanium alloy · PCD tool
1 Introduction Titanium alloys have been used in the aerospace industry due to its high strength-to-weight ratio (around 260 N · m/kg), the need to reduce fuel consumption and emissions, and higher resistance to fracture under fatigue [1]. The most common titanium alloy is Ti6Al4V, originally developed for aircraft structural applications in the 1950’s, and now accounts for more than 50% of the titanium alloy world market share. In medical applications, they are also chosen because of their oxidation resistance and bio-compatibility to manufacture surgical tools, dental and orthopedic implants, cardiovascular stents, artificial valves, and crane-facial plates and screws, constantly subjected to static and fatigue loads [2]. Anna Carla Araujo
[email protected] 1
Arts et Metiers Institute of Technology, LaBoMaP, UBFC, HESAM Universit´e, Cluny, F-71250, France
2
PEM/COPPE, Universidade Federal do Rio de Janeiro, Rio de Janeiro, Brazil
3
INSA-Toulouse, Institut Cl´ement Ader (ICA), Universit´e de Toulouse, Toulouse, France
4
Saint Jean Tooling, Saint Jean d’Ardi`eres, 69220, France
The manufacturing of Ti6Al4V relies on casting and forging or, nowadays, additive manufacturing (DED, SLM, or EBM), followed by subsequent machining [3]. Machining titanium alloys is not an easy task because a low heat dissipation causes very high temperatures near the cutting edge [4]. Ti6Al4V thermal conductivity is 7.1 W/m · K and specific heat around 553 L/kg · K). Also, this material has low elastic modulus (110 GP
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