Abstract
This paper focused on combined study on the evolution of tool wear and its influence on borehole quality in dry helical milling of Ti-6Al-4V. The carbide tools with TiAlN coating were used in this experimental investigation. The tool wear characteristics both at front and periphery cutting edges were investigated using an optical microscope and SEM-EDS techniques. The experimental results demonstrate that the combined effects of chipping/fracture, diffusion, and oxidation have significant bearings on front cutting edge failure, while the flank wear was predominant at the periphery cutting edges. The cutting speed was correlated with tool failure mechanizes, and the different wear rates at front and periphery cutting edge caused different variation trends of cutting force in thrust and horizontal direction during hole-making process. The quality of machined holes was evaluated in terms of geometry accuracy, burr formation, and surface roughness. The exit-burrs of machined hole were closely correlated with front cutting edge wear. However, high hole quality was observed even the near end of tool life from the point of view of diameters, roundness error, and surface finish due to the smooth wear pattern at periphery cutting edges. Severe tool wear at front cutting edges will cause excessive exit-burrs, but it has no obvious effect on geometry and surface roughness in helical milling of Ti-6Al-4V.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Boyer RR (1996) An overview on the use of titanium in the aerospace industry. Mater Sci Eng A 213(1-2):103–114
Molinari A, Musquar C, Sutter G (2002) Adiabatic shear banding in high speed machining of Ti6Al4V: experiments and modeling. Int J Plast 18(4):443–459
López de Lacalle LN, Pérez J, Llorente JI, Sánchez JA (2000) Advanced cutting conditions for the milling of aeronautical alloys. J Mater Process Tech 100(1-3):1–11
Kramer BM (1986) A comprehensive tool wear model. CIRP Annals Manuf Technol 35(1):67–70
Venugopal KA, Paul S, Chattopadhyay AB (2007) Growth of tool wear in turning of Ti-6Al-4V alloy under cryogenic. Wear 262(9–10):1071–1078
Wanigarathne PC, Kardekar AD, Dillon OW, Poulachon G, Jawahir IS (2005) Progressive tool-wear in machining with coated grooved tools and its correlation with cutting temperature. Wear 259(7–12):1215–1224
Zhang S, Li JF, Sun J, Jiang F (2010) Tool wear and cutting forces variation in high-speed end-milling Ti-6Al-4V alloy. Int J Adv Manuf Technol 46(1-4):69–78
Mantle AL, Aspinwall DK, Wollenhofer O (1995) Twist drill of gamma titanium aluminade intermetallics. In: Proceedings of the 12th conference of the Irish manufacturing committee. University College Cork. September 6–8, pp 229–236
Li AH, Zhao J, Luo HB, Pei ZQ, Wang ZM (2012) Progressive tool failure in high-speed dry milling of Ti-6Al-4V alloy with coated carbide tools. Int J Adv Manuf Technol 58(5–8):465–478
Sun J, Guo YB (2009) Material flow stress and failure in multiscale machining titanium alloy Ti-6Al-4V. Int J Adv Manuf Technol 41(7–8):651–659
Özel T, Sima M, Srivastava AK, Kaftanoglu B (2010) Investigations on the effects of multi-layered coated inserts in machining Ti-6Al-4V alloy with experiments and finite element simulations. CIRP Annals - Manuf Technol 59(1):77–82
Chen G, Ren CZ, Yang XY, Jin XM, Guo T (2011) Finite element simulation of high-speed machining of titanium alloy (Ti-6Al-4V) based on ductile failure model. Int J Adv Manuf Technol 56(9–12):1027–1038
Qin XD, Chen SM, Liu WC (2009) Development and application of helical milling technology in the aviation manufacturing and assembly industry. Aeronaut Manuf Technol 6:58–60. (in Chinese)
Iyer R, Koshy P, Ng E (2007) Helical milling: an enabling technology for hard machining precision holes in AISI D2 toolsteel. Int J Mach Tools Manuf 47(2):205–210
Denkena B, Boehnke D, Dege JH (2008) Helical milling of CFRP-titanium layer compounds. CIRP J Manuf Sci Technol 1(2):64–69
Brinksmeier E, Fangmann S, Meyer I (2008) Orbital drilling kinematics. Prod Eng Res Devel 2(3):277–283
Li Z, Liu Q (2013) Surface topography and roughness in hole-making by helical milling. Int J Adv Manuf Technol 66(9–12):1415–1425
Wang HY, Qin XD, Ren CZ, Wang Q (2012) Prediction of cutting forces in helical milling process. Int J Adv Manuf Technol 58(9–12):849–859
Canteroa JL, Tardío MM, Canteli JA, Marcos M, Miguéle MH (2005) Dry drilling of alloy Ti-6Al-4V. Int J Mach Tools Manuf 45(11):1246–1255
Harris SG, Vlasveld AC, Doyle ED, Dolder PJ (2000) Dry machining commercial viability through filtered arc vapour deposited coatings. Surf Coat Technol 133–134:383–388
Herbert CRJ, Kwong J, Kong MC, Axintea DA, Hardy MC, Withers PJ (2012) An evaluation of the evolution of workpiece surface integrity in hole making operations for a nickel-based superalloy. J Mater Process Technol 212(8):1723–1730
Sharman ARC, Amarasinghe A, Ridgway K (2008) Tool life and surface integrity aspects when drilling and hole making in Inconel 718. J Mater Process Technol 200:424–432
Biermann D, Heilmann M, Kirschner M (2011) Analysis of the influence of tool geometry on surface integrity in single-lip deep hole drilling with small diameters. Procedia Eng 19:16–21
Wang Z (1997) Machining of aerospace superalloys with coated (PVD and CVD) carbides and self-propelled rotary tools. PhD Thesis. South Bank University, UK
Lin TR (2002) Cutting behaviour of a TiN-coated carbide drill with curved cutting edges during the high-speed machining of stainless steel. J Mater Process Technol 127(1):8–16
Sharman ARC, Dewes RC, Aspinwall DK (2001) Tool life when high speed ball nose end milling of Inconel 718. J Mater Process Technol 118(1–3):29–35
Nabhani F (2001) Machining of aerospace titanium alloys. Robot Comput-Integr Manuf 17(1–2):99–106
Min W, Youzhen Z (1988) Diffusion wear in milling titanium alloys. Mater Sci Technol 4(6):548–553
Astakhov VP (2004) The assessment of cutting tool wear. Int J Mach Tools Manuf 44(6):637–647
Ezugwu EO, Wang ZM (1997) Titanium alloys and their machinability—a review. J Mater Process Technol 68(3):262–274
Childs T, Maekawa K, Obikawa T, Yamane Y (2000) Metal machining: theory and applications. Wiley, New York
Bono M, Hi J (2001) The effects of thermal distortions on the diameter and cylindricity of dry drilled holes. Int J Mach Tools Manuf 41(15):2261–2270
Stephenson DA, Agapiou JS (1997) Metal cutting theory and practice. Marcel Dekker, New York, p 435
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Li, H., He, G., Qin, X. et al. Tool wear and hole quality investigation in dry helical milling of Ti-6Al-4V alloy. Int J Adv Manuf Technol 71, 1511–1523 (2014). https://doi.org/10.1007/s00170-013-5570-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-013-5570-0