M.

Tech in Advanced Manufacturing & Production Management

Seminar-1(MMEMP 108)

1. INTRODUCTION

Titanium alloy has very high strength, high specific strength, superior corrosion and creep resistances, biocompatibility, and some other favorable properties. Thus, it is applied widely to aerospace engine and fuselage, marine elements and structures, cryogenic vessels, artificial joints, implants, etc. However, it is very difficult to machine this alloy at higher cutting speeds because this alloy has very strong chemical affinity with tool materials and quite low thermal conductivity in addition to very high strength. These properties not only increase cutting temperature and stresses on the cutting tool, but also shorten the tool life and deteriorate the integrity of finished surface. Besides, this alloy is likely to produce serrated chips with repeatedly adiabatic shear localization, which often causes chatter vibration at higher frequency excited by chip segmentation and localized shear. Thus, ceramic tools suffer from notching and chipping easily. To increase cutting speed of titanium alloy, theoretical, experimental and numerical studies have been conducted for many years. Extremely hard tool materials, such as single crystal diamond, polycrystalline diamond, binder-less polycrystalline cubic boron nitride, were applied to machining this alloy. Machining using a rotary tool and high pressure coolant were applied to decrease cutting temperature Many coated carbide tools also have been developed for machining this alloy at higher cutting speeds. However, with these tools, it is difficult to increase cutting speeds practically. Thus, uncoated cemented carbides are still standard tools for machining this alloy. Polycrystalline diamond tools are also used only if their cost can be compensated with their high performance

Here new techniques involving Air jet assisted machining and usages of cryogenic coolants were proposed as solution for machining difficulties of titanium alloys. An experimental result showed the potential of AJA machining of titanium alloy. In this study, AJA machining was applied to high speed finish-turning of Ti-6Al-4V, and then, the influences of the application direction of cutting fluid to the tool
Dept. of Mechanical Engineering, SJCET, Palai

M.Tech in Advanced Manufacturing & Production Management

Seminar-1(MMEMP 108)

tip and the cutting speed on the tool life and surface finish were investigated. Temperature inside the insert was measured with a thermocouple in AJA, conventional wet and dry cuttings. From the results, the mechanisms of air jet assistance in the enhancement of heat transfer coefficient from the cutting tool to the cutting fluid were discussed.

In the other method cryogenic machining were introduced in which cryogenic coolants were used for machining purposes. A cryogenic coolant, due to its extreme low temperature and its easiness to flow, reduces the cutting temperature effectively by penetrating efficiently in the chip-tool contact region . Thus, cryogenic machining is carried out to lower the cutting temperature and to enhance the chemical stability of the work piece and cutting tool and is expected to improve the productivity level in machining of titanium and its alloys

Dept. of Mechanical Engineering, SJCET, Palai