Machinability study of Ti-6Al-4V alloy using solid lubricant
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Sådhanå (2020)45:250 https://doi.org/10.1007/s12046-020-01405-2
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Machinability study of Ti-6Al-4V alloy using solid lubricant ASIT KUMAR PARIDA* , PARUCHURI VENKATSWAR RAO and SUDARSAN GHOSH Department of Mechanical Engineering, Indian Institute of Technology, Delhi, India e-mail: [email protected] MS received 21 January 2020; revised 18 April 2020; accepted 29 May 2020 Abstract. Cutting tool suffers rapidly during machining titanium-based alloys due to low thermal conductivity. Thus most of the heat is concentrated on the tool rather than chip during machining. To overcome this problem, a suitable cutting parameter, tool geometry, and sustainable methods are necessary. This paper presents the effect of MoS2 solid lubricant (SL), cutting speed, and nose radius during turning of Ti-6Al-4V alloy using the TiAlN coated carbide tool. The experiments are performed at different cutting speeds, nose radius, and flow rates of solid lubricant to study tool wear, surface roughness, and chip morphology. The results show that the use of solid lubricant reduces the tool wear (37%), and the surface roughness (65%) compared to the dry cutting. Similarly, the effects of nose radius and cutting speed have also been studied for both conditions. Keywords.
Ti-6Al-4V; solid lubricant; MoS2; tool wear; surface roughness; chip morphology.
1. Introduction Low density, good resistance to wear, and high strength properties of titanium alloys enable their wide applications in automobile, bio-medical equipment, aeronautic sectors, and defense applications [1–3]. However, several phenomena occur during machining of these alloys, such as rapid tool wear, fluctuation of cutting forces, and the formation of segment chips [4]. This is happening due to low thermal conductivity (which does not allow heat to dissipate from the cutting zone), low elastic modulus (spring back effect), and chemical reaction to all cutting tool materials [5]. The tool-chip interface temperature that is generated during machining titanium alloy is a place of complex interactions between mechanical and thermal phenomena. The surface of the tool in contact with the chip undergoes various forms of wear mechanisms such as adhesion, abrasion, and diffusion. The quality of the machined surface and tool life depends largely on the conditions under which the cut is made. In particular, the use of cutting fluids is an important parameter since it limits the rise in temperature in the cutting areas. The presence of a fluid film between the different surfaces, reduces friction, has been reported by researchers. The heat generated at the chip-tool interface in the machining of Ti-6Al-4V can reach values even more than 1000°C. Though the use of cutting fluids improves machinability; however, it is harmful to the operators and pollutes the environment. To protect the environment, the current trend is to limit, and even eliminate, the use of cutting fluids [6]. Mia and Dhar [7] used *For correspondence
pressurized jet co
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