Investigation of tool wear and energy consumption in machining Ti6Al4V alloy with uncoated tools.

Younas, Muhammad; Khan, Mushtaq; Jaffery, Syed Husain Imran; Khan, Zarak; Khan, Nawar

Abstract

This research studies the energy consumption and wear mechanism of carbide cutting tools in dry machining of Ti6Al4V alloy. In the first phase of experiments, full factorial design experiments were employed to study the tool wear rate (R) and specific cutting energy (SCE) with respect to the machining conditions (cutting speed and feed rate). Results showed that machining responses such as tool wear and energy consumption are affected by cutting conditions, thus requiring investigation to understand the wear mechanisms. Therefore, in the second phase, additional experiments were performed to investigate the tool-workpiece interactions at the cutting conditions reported to have low, moderate, and high tool wear. It was revealed that strong adhesion and material transfer between the tool and workpiece caused high wear. Electron dispersive X-ray spectroscopy (EDX) analysis of worn tools showed that the transfer of tungsten (W) and cobalt (Co) to the workpiece and titanium to the tool surface is the primary cause of tool deterioration. As a result, diffusion and dissolution have degraded cutting performance and weakened the tool edge, leading to rapid wear. Furthermore, worn tools resulted in relatively higher energy consumption per unit volume of material removed at the tooltip. The degradation of cutting performance and weakening of the tool edge results in rapid wear and higher energy consumption. The study suggests that minimizing tool wear is crucial for energy reduction, improved sustainability, and cleaner production goals in dry machining of titanium-based alloys.

Citation

YOUNAS, M., KHAN, M., JAFFERY, S.H.I., KHAN, Z. and KHAN, N. 2024. Investigation of tool wear and energy consumption in machining Ti6Al4V alloy with uncoated tools. International journal of advanced manufacturing technology [online], 132(7-8), pages 3785-3799. Available from: https://doi.org/10.1007/s00170-024-13548-1

• Journal Article Type: Article
• Acceptance Date: Apr 5, 2024
• Online Publication Date: Apr 16, 2024
• Publication Date: Jun 30, 2024
• Deposit Date: Apr 17, 2024
• Publicly Available Date: Apr 23, 2024
• Journal: International journal of advanced manufacturing technology
• Print ISSN: 0268-3768
• Electronic ISSN: 1433-3015
• Publisher: Springer
• Peer Reviewed: Peer Reviewed
• Volume: 132
• Issue: 7-8
• Pages: 3785-3799
• DOI: https://doi.org/10.1007/s00170-024-13548-1
• Keywords: Cutting tools; Wear; Energy consumption; Carbide cutting; Tool wear; Titanium alloys; Wear mechanisms; Dry machining
• Public URL: https://rgu-repository.worktribe.com/output/2298560