Tool wear progression and its effects on energy consumption and surface roughness in cryogenic assisted turning of Ti-6A
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ORIGINAL ARTICLE
Tool wear progression and its effects on energy consumption and surface roughness in cryogenic assisted turning of Ti-6Al-4V Chetan Agrawal 1 & Navneet Khanna 1 & Catalin Iulian Pruncu 2,3,4 & Anil Kumar Singla 5 & Munish Kumar Gupta 6 Received: 8 June 2020 / Accepted: 22 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This work evaluates the machinability improvements in vastly used titanium alloy (Ti-6Al-4V) using alternate turning techniques. Detailed examination of flank and crater faces of inserts is carried out in this work to analyze tool wear under dry, wet, and cryogenic environments. Critical responses such as crater wear and energy consumption decide the machinability of materials, but these responses are less explored in the past using altered cutting conditions. This investigation analyzes the machinability in terms of industry-relevant responses such as tool wear, energy consumption, chip reduction coefficient, and average surface roughness under altered cutting conditions. Outcomes of this investigation show increase in tool life by 200% and 80% using cryogenic turning than in dry and wet turning techniques, respectively. Moreover, the findings of the study show up to 9% and 61% decline in energy consumption using cryogenic turning than in dry and wet turning, respectively. Surface roughness values also show a reduction by up to 71% and 64%, under cryogenic environment than in dry and wet environments, respectively. The results of this study advocate the suitability of cryogenic turning at industry-relevant parameters to establish this technique as a viable alternative to replace inefficient conventional turning techniques. Keywords Flank wear . Crater wear . Cryogenic turning . Titanium alloy . Energy assessment . Surface quality
1 Introduction Ti-6Al-4V is a high-performance heat-resistant alloy mostly used in aero, auto, defense, marine, and medical industries [1]. However, conventional machining of Ti-6Al-4V is not productive and energy-efficient; also, it is not sustainable as it leads to an increase in carbon emissions [2]. It has concerned
* Navneet Khanna [email protected]
2
Mechanical Engineering, School of Engineering, University of Birmingham, Birmingham B15 2TT, UK
3
Mechanics of Materials Division, Department of Mechanical Engineering, Imperial College London, London, UK
Chetan Agrawal [email protected]
4
Design, Manufacturing & Engineering Management, University of Strathclyde, Glasgow, Scotland G1 1XJ, UK
Catalin Iulian Pruncu [email protected]
5
Department of Mechanical Engineering, SLIET, Longowal, Punjab 148106, India
6
Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan, People’s Republic of China
* Munish Kumar Gupta [email protected]
Anil Kumar Singla [email protected] 1
research communities to counter the negative effects due to the manufacturing activities on the environme
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