Effects of Coolants on Improving Machining Parameters while Mach-Inability Titanium Alloy (Ti-6Al-4V): A Review

Abstract:

In this review, present day, the best versatile material Titanium alloy (Ti-6Al-4V) plays the most vital role in the manufacturing of aero engines as a base material. It has been observed that machining this type of alloys is the complicated tasks with optimum machining results. This research investigates the consequences of machining parameters by making use three types of technique: firstly, nitrogen gas technique; secondly, high pressure coolant (HPC); thirdly, cryogenic cooling technique as the coolant’s techniques compared to the normal coolant. Utilizing liquid nitrogen and gas nitrogen as a coolant will decrease friction, heat at the cutting zone, surface roughness, the amount of power consumed in a metal cutting process in addition significantly increase the tool life, dimensional accuracy and so improve the productivity.

• Periodical: Applied Mechanics and Materials (Volumes 110-116)
• Pages: 1657-1666
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.110-116.1657
• Online since: October 2011
• Authors: Moaz H. Ali, R. Balasubramanian, Bashir Mohamed, Basim A. Khidhir
• Keywords: Component, Coolant, Improving Machining, Titanium Alloy

References

[1] S. Sharma a, ManuDogra b, N.M. Suri c. Cooling techniques for improved productivity in turning[J]. International Journal of Machine Tools & Manufacture, 49 (2009) 435–453.

DOI: 10.1016/j.ijmachtools.2008.12.010

[2] Geoffrey Boothroyd, Winston A. Knight, Fundamentals of Machining and Machine Tools, third ed, CRC Taylor & Francis, (2005).

[3] H. Zhao, G.C. Barber, Q. Zou, A study of flank wear in orthogonal cutting with internal cooling, Wear 253 (2002) 957–962.K. Elissa, Title of paper if known, unpublished.

DOI: 10.1016/s0043-1648(02)00248-x

[4] T.H.C. Childs, K. Maekawa, T. Obikawa, Y. Yamane, Metal Machining Theory and Applications, Butterworth Heinemann, Oxford, (2001).

[5] E.M. Trent, P.K. Wright, Metal Cutting, fourth ed, Butterworth Heinemann, Oxford, 2000. A. Rahmath Zareena, M. Rahman, Y.S. Wong, Binderless CBN tools, a breakthrough for machining titanium alloys, Journal of Manufacturing Science and Engineering 127 (2005).

DOI: 10.1115/1.1852570

[6] G. Barrow, A review of experimental and theoretical techniques for assessing cutting temperatures, Annals of the CIRP 22 (2) (1973) 203–211.

[7] Ying-lin1, 2, Hui-yue1, LIU Gang1, ZHANG Ming1. Use of nitrogen gas in high-speed milling of Ti-6Al-4V [J]. Trans. Nonferrous Met. Soc. China 19(2009) 530-534.

DOI: 10.1016/s1003-6326(08)60307-6

[8] Palanisamy , D. McDonald, S. Dargusch. Effects of coolant pressure on chip formation while turning Ti6Al4V alloy [J]. International Journal of Machine Tools & Manufacture 49 (2009) 739–743.

DOI: 10.1016/j.ijmachtools.2009.02.010

[9] E.O. Ezugwu Z.M. Wang, Titaniumalloysandtheirmachinability—a review, Journal ofMaterialProcessingTechnology68(1997)262–274.

[10] E.O. Ezugwu, Key improvements in the machining of difficult-to-cut aero- space superalloys, International Journal of Machine Tools and Manufacture 45 (12–13) (2005) 1353–1367.

DOI: 10.1016/j.ijmachtools.2005.02.003

[11] E.O. Ezugwu, J. Bonney, R.B. Da Silva, O. Cakir, Surface integrity of finished turned Ti–6Al–4V alloy with PCD tools using conventional and high pressure coolant supplies, International Journal of Machine Tools and Manufacture 47 (6) (2007).

DOI: 10.1016/j.ijmachtools.2006.08.005

[12] A.R. Machado, J. Wallbank, E.O. Ezugwu, I.R. Pashby, Tool performance and chip control when machining Ti–6Al–4V and Inconel 901 using high pressure coolant supply, Machining Science and Technology 2 (1998) 1–12.

DOI: 10.1080/10940349808945655

[13] K. Sorby, K. Tonnessen, High-pressure cooling of face-grooving operations in Ti6Al4V, Proceedings of Mechanical Engineering Part B: Journal of Engineer- ing Manufacturing 220 (2006) 1621–1627.

DOI: 10.1243/09544054jem474

[14] M. Vosough, I. Svenningsson. Influence of high pressure water-jet assisted machining on surface residual stresses on the work-piece of Ti–6Al–4V Alloy, in: Proceeding of SPIE, SPIE, Singapore, Bellingham, (2004).

DOI: 10.1117/12.621449

[15] A.R. Zareena, M. Rahman, Y.S. Wong, High speed machining of aerospace alloy TI–6Al–4V, in: Proceedings of the 33rd International SAMPE Technical Conference, Seattle, United States, (2001).

[16] A.E. Diniz, R. Micaroni, Influence of the direction and flow rate of the cutting fluid on tool life in turning process of AISI 1045 steel, International Journal of Machine Tools and Manufacture 47 (2) (2007) 247–254.

DOI: 10.1016/j.ijmachtools.2006.04.003

[17] E.O. Ezugwu, R.B. Da Silva, J. Bonney, A.R. Machado, Evaluation of the performance of CBN tools when turning Ti–6Al–4V alloy with high pressure coolant supplies, International Journal of Machine Tools and Manufacture 45 (9) (2005) 1009–1014.

DOI: 10.1016/j.ijmachtools.2004.11.027

[18] L.N. Lo'pez de Lacalle, etal., Using high pressure coolant in the drilling and turning of low machinability alloys, International Journal of Advanced Manufacturing Technology16(2000)85–91.

DOI: 10.1007/s001700050012

[19] M.A. EI. Baradie, Cutting fluids, Part I. Characterisation, Journal of Materials Processing Technology 56 (1996) 787–797.

DOI: 10.1016/0924-0136(95)01892-1

[20] T.C. Jen, G. Gutierrez, S. Eapen, G. Barber, H. Zhao, P.S. Szuba, J. Lambataille, J. Manjunathaiah, Investigation of heat pipe cooling in drilling application, Part 1: preliminary numerical analysis and verification, International Journal of Machine Tools & Manufacture 43 (2002).

DOI: 10.1016/s0890-6955(01)00155-9

[21] YILDIZ Y, NALBANT M. A review of cryogenic cooling in machining processes [J]. International Journal of Machine Tools andManufacture 2008, 48(9): 947−964.

DOI: 10.1016/j.ijmachtools.2008.01.008

[22] D.P. Adler, W.S. Hii, D.J. Michalek, J.W. Sutherland, Examining the role of cutting fluids in machining and efforts to address associated environmental/health concerns, Machining Science and Technology 10 (2006) 23–58.

DOI: 10.1080/10910340500534282

[23] W.A. Carter, Metal Machining, Part VI, Cutting Fluids, Machinery Lloyd, Overseas Edition, (1956).

[24] Ali Khan, I. Ahmed. Improving tool life using cryogenic cooling [J]. Journal of materials processing technology, 196 (2008) 149–154.

DOI: 10.1016/j.jmatprotec.2007.05.030

[25] Ezugwu, E.O., Bonney, J., Rosemar, B., Da Silva, B., C¸ akir, O., 2007. Surface integrity of finished turned Ti–6Al–4V alloy with PCD tools using conventional and high pressure coolant supplies. Int. J. Mach. Tool Manuf. 47 (6), 884–891.

DOI: 10.1016/j.ijmachtools.2006.08.005

[26] Hong, S.Y., Markus, I., Jeong, W.C., 2001. New cooling approach and tool life improvement in cryogenic machining of titanium alloy Ti–6Al–4V. Int. J. Mach. Tool Manuf. 41 (15), 2245–2260.

DOI: 10.1016/s0890-6955(01)00041-4

[27] Hong, S.Y., Ding, Y., 2001. Cooling approaches and cutting temperatures in cryogenic machining of Ti–6Al–4V. Int. J. Mach. Tool Manuf. 41 (10), 1417–1437.

DOI: 10.1016/s0890-6955(01)00026-8

[28] LI Liang. Study on the mechanism and process of high speed milling of titanium alloys [D]. Nanjing: Nanjing University of Aeronautics and Astronautics, 2004. (in Chinese).

[29] ISO, Tool-Life Testing with Single-Point Turning Tools-ISO 3685, International Organization for Standardization, (1993).