Influence of tool material on forces, temperature, and surface quality of Ti-15333 alloy in CT and UAT

Document Type : Article


1 Department of Mechanical Engineering, CECOS University of IT & Emerging Sciences, Peshawar, KPK, Pakistan

2 Faculty Of Industrial Engineering, UET Peshawar Jalozai Campus, Pakistan

3 Department of Mechanical and Industrial Engineering, Sultan Qaboos University, Musqat, Oman

4 Wolfson School of Mechanical, Electrical and Manufacturing Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, UK


Ultrasonically assisted turning (UAT) is a progressive machining method in which vibration is applied to the cutting insert in the direction of the cutting tool velocity to reduce the cutting forces, significantly and increase the surface finish noticeably. However, the key question about the tool damage caused by the vibration and its effect on the cutting forces, surface roughness and process zone temperature is still unknown in UAT.
This paper presents experimental analysis of the effect of worn tool in UAT and conventional-turning (CT) of β-Ti-15V-3Al-3Cr-3Sn (Ti-15333) alloy on surface quality of a machined surface, temperature of the process zone and cutting forces using KC5510 (PVD TiAlN) and CP500 (PVD (Ti,Al)N-TiN) cutting inserts.  In UAT, the tool edge damages in CP500 inserts increased with tested machining time resulted a growth of 8 N and 10 N in tangential force component in CT and UAT, respectively.  Similarly, with the progression of tool edge damage, a growth of 1.7% and 9.3% in process zone temperature was observed in CT and UAT, respectively.  The surface roughness results revealed a gradual degradation with machining time, however, the results UAT with a worn tool was significantly better when compared to CT, with a virgin tool.


Main Subjects

1.Peters, M. and Leyens, C., Titanium and Titanium Alloys, Wiley-VCH; Germany (2002).
2. Ucun, I., Aslantas, K., and Bedir, F. An experimental investigation of the e_ect of coating material on tool wear in micro milling of Inconel 718 super alloy", Wear, 300(1-2), pp. 8-19 (2013).
3. _Avila, R.F., Mancosu, R.D., Machado, A.R., Vecchio, S.D., da Silva, R.B., and Vieira, J.M. Comparative analysis of wear on PVD TiN and (Ti1-x Alx)N coatings in machining process", Wear, 302(1-2), pp. 1192-1200 (2013).
4. Ezugwu, E., Da Silva, R.B., Bonney, J., and Machado, A.R. Evaluation of the performance of CBN tools when turning Ti-6Al-4V alloy with high pressure coolant supplies", Int. J. of Mach. Tools and Manuf., 45, pp. 1009-1014 (2005). 5.  Ozel, T. Computational modelling of 3D turning: Inuence of edge micro-geometry on forces, stresses, friction and tool wear in PcBN tooling", J. of Mater. Proc. Tech., 209, pp. 5167-5177 (2009). 6. Mkaddem, A., Soussia, A.B., and Mansori, M.E. Wear resistance of CVD and PVD multilayer coatings when dry cutting _ber reinforced polymers (FRP)", Wear, 302(1-2), pp. 946-954 (2013). 7. M'Saoubi, R., Johansson, M.P., and Andersson, J.M., Wear mechanisms of PVD-coated PCBN cutting tools", Wear, 302(1-2), pp. 1219-1229 (2013). 8. Dhar, N.R., Kishore, S.V.N., Paul, S., and Chattopadhyay, A.B., The e_ects of cryogenic cooling on chips and cutting forces in turning AISI 1040 and AISI 4320 steel", J. of Eng. Manuf., 216-part B, pp. 713-724 (2002). 9. Bermingham, M.J., Kirsch, J., Sun, S., Palanisamy, S., and Dargusch, M.S., New observations on tool life, cutting forces and chip morphology in cryogenic machining Ti-6Al-4V", Int. J. of Mach. Tools and Manuf, 51(6), pp. 500-511 (2011). 10. Dhananchezian, M. and Kumar, P.M. Cryogenic turning of the Ti-6Al-4V alloy with modi_ed cutting tool inserts", Cryogenics, 51, pp. 34-40 (2011). 11. Machai, C. and Biermann, D. Machining of titaniumalloy Ti-10V-2Fe-3Al under cryogenic conditions: cooling with carbon dioxide snow", J. of Mater. Proc. Tech, 211, pp. 1175-1183 (2011). 12. Wang, Z.Y., Rajurkar, K.P., Fan, J., Lei, S., Shin, Y.C., and Petrescu, G. Hybrid machining of Inconel 718", Int. J. of Mach. Tools and Manuf, 43(13), pp. 1391-1396 (2003). 13. Dandekar, C.R., Shin, Y.C., and Barnes, J. Machinability improvement of titanium alloy (Ti-6Al-4V) via LAM and hybrid machining", Int. J. of Mach. Tools and Manuf, 50(2), pp. 174-182 (2010). 14. Muhammad, R., Maurotto, A., Demiral, M., Roy, A., and Silberschmidt, V.V. Thermally enhanced ultrasonically assisted machining of Ti alloy", CIRP J. of Manuf. Sci. and Tech, 7(2), pp. 159-167 (2014). 15. Muhammad, R., Hussain, M.S., Maurotto, A., Siemers, C., Roy, A., and Silberschmidt, V.V. Analysis of a free machining _ + _ titanium alloy using conventional and ultrasonically assisted turning", J. of Mater. Proc. Tech, 214(4), pp. 906-915 (2014). 16. Maurotto, A., Siemers, C., Muhammad, R., Roy, A., and Silberschmidt, V.V. Ti alloy with enhanced machinability in UAT turning", Metall. and Mater. Trans. A, 45(6), pp. 2768-2775 (2014). 17. Muhammad, R., Roy, A., and Silberschmidt, V.V. Finite element modelling of conventional and hybrid oblique turning processes of titanium alloy", Proc. CIRP, 8, pp. 509-514 (2013). 18. Muhammad, R., Demiral, M., Roy, A., and Silberschmidt, V.V. Modelling the dynamic behaviour of hard-to-cut alloys under conditions of vibro-impact cutting", J. of Phy.: Conf. Ser., 451, pp. 1-11 (2013). 19. Maurotto, A., Muhammad, R., Roy, A., and Silberschmidt, V.V. Enhanced ultrasonically assisted turning of a _-Titanium alloy", Ultrasonics, 53(7), pp. 1242-1250 (2013). 20. Nategh, M.J., Razavi, H., and Abdullah, A. Analytical modeling and experimental investigation of ultrasonic-vibration assisted oblique turning, part I: Kinematics analysis", Int. J. of Mech. Sci., 63(1), pp. 1-11 (2012). 21. Muhammad, R., Maurotto, A., Roy, A., and Silberschmidt, V.V. Ultrasonically assisted turning of Ti- 6Al-2Sn-4Zr-6Mo", J. of Phy.: Conf. Ser., 382, pp. 1-12 (2012). 22. Muhammad, R., Ahmed, N., Roy, A., and Silberschmidt, V.V. Turning of advanced alloys with vibrating cutting tool", Solid State Phenom., 188, pp. 277-284 (2012). 23. Muhammad, R., Ahmed, N., Roy, A., and Silberschmidt, V.V. Numerical modelling of vibrationassisted turning of Ti-15333", Proc. CIRP, 1, pp. 347- 352 (2012). 24. Maurotto, A., Muhammad, R., Roy, A., Babitsky, V.I., and Silberschmidt, V.V. Comparing machinability of Ti-15-3-3-3 and Ni-625 alloys in UAT", Proc. CIRP, 1, pp. 330-335 (2012). 25. Mitrofanov, A.V., Babitsky, V.I., and Silberschmidt, V.V. Thermomechanical _nite element simulations of ultrasonically assisted turning", Comput. Mater. Sci., 32, pp. 463-471 (2005). 26. Sharman, A., Bowen, P., Aspinwall, D., and Dewes, C., Ultrasonic Assisted Turning of Gamma Titanium Aluminide, Rolls-Royce PLC (2001). 27. Kumabe, J., Fuchizawa, K., Soutome, T., and Nishimoto, Y. Ultrasonic superposition vibration cutting of ceramics", Prec. Eng., 11(2) pp. 71-77 (1989). 28. Ahmed, N., Mitrofanov, A.V., Babitsky, V.I., and Silberschmidt, V.V. Stresses in ultrasonically assisted turning", App. Mech. and Mater., 5, pp. 351-358 (2006). 29. Muhammad, R., Maurotto, A., Roy, A., and Silberschmidt, V.V. Hot ultrasonically assisted turning of _-Ti alloy", Proc. CIRP, 1, pp. 336-341 (2012). 30. Muhammad, R., Maurotto, A., Roy, A., and Silberschmidt, V.V. Analysis of forces in vibro-impact and hot vibro-impact turning of advanced alloys", App. Mech. and Mater., 70, pp. 315-320 (2011). 31. Muhammad, R., Ahmed, N., Ullah, H., Roy, A., and Silberschmidt, V.V. Hybrid machining process: Experimental and numerical analysis of hot ultrasonically assisted turning", Int. J. Adv. Manuf. Tech., 97, pp. 2173-2192 (2018). 32. Muhammad, R., Ahmed, N. Ullah, H., and Silberschmidt, V.V. Dynamic behaviour of _-Ti-15333 in ultrasonically assisted turning: Experimental and numerical analysis", Scientia Iranica, Transac. B: Mech. Engg, 24(6), pp. 2904-2914 (2017). 33. Exner, H.E. and Gurland, J.A. A review of parameters inuencing some mechanical properties of tungsten carbide cobalt alloys", Powd. Metall., 13, pp. 13-31 (1970). 34. Mills, B. and Redford, A.H. Machinability of Engineering Materials, London; New York, Applied Science Publishers (1983). 35. Muhammad, R, Mistry, A, Khan, S. W, Ahmed, N., Roy, A., and Silberschmidt, V. V., Analysis of tool wear in ultrasonically assisted turning of _-Ti- 15V-3Al-3Cr-3Sn alloy" Scientia Iranica, Transac. B: Mech. Engg., 23(4), pp. 1800-1810 (2016). 36. Komanduri, R. and Hou, Z.B. On thermoplastic shear instability in the machining of a titanium alloy (Ti-6Al- 4V)", Metall. and Mater. Trans. A, 33(9), pp. 2995- 3010 (2002). 37. Ulutan, D. and Ozel, T. Machining induced surface integrity in titanium and nickel alloys: A review", Int. J. of Mach. Tools and Manuf, 51(3), pp. 250-280 (2011).