Skip to content
Licensed Unlicensed Requires Authentication Published by De Gruyter May 23, 2016

Effect of cutting parameters on workpiece and tool properties during drilling of Ti-6Al-4V

Auswirkung der Schneidparameter auf die Werkstück- und Werkzeugeigenschaften beim Bohren von Ti-6Al-4 V
  • Yahya Hışman Çelik , Hakan Yildiz and Cebeli Özek
From the journal Materials Testing

Abstract

The main aim of machining is to provide the dimensional preciseness together with surface and geometric quality of the workpiece to be manufactured within the desired limits. Today, it is quite hard to drill widely utilized Ti-6Al-4 V alloys owing to their superior features. Therefore, in this study, the effects of temperature, chip formation, thrust forces, surface roughness, burr heights, hole diameter deviations and tool wears on the drilling of Ti-6Al-4 V were investigated under dry cutting conditions with different cutting speeds and feed rates by using tungsten carbide (WC) and high speed steel (HSS) drills. Moreover, the mathematical modeling of thrust force, surface roughness, burr height and tool wear were formed using Matlab. It was found that the feed rate, cutting speed and type of drill have a major effect on the thrust forces, surface roughness, burr heights, hole diameter deviations and tool wears. Optimum results in the Ti-6Al-4 V alloy drilling process were obtained using the WC drill.

Kurzfassung

Das Hauptziel der maschinellen Bearbeitung besteht darin, die dimensionale Präzision sicherzustellen, zusammen mit einer guten Oberflächenqualität und geometrischen Qualität des Werkstückes, das jeweils unter den gegebenen Randbedingungen hergestellt werden muss. Heute ist es immer noch schwer, die vielfach genutzten Ti-6Al-4V-Legierungen aufgrund ihrer überragenden Eigenschaften zu drehen. Deshalb wurden in der diesem Beitrag zugrunde liegenden Studie die Temperatur, die Spanbildung, die Wirkkräfte, die Oberflächenrauheit, die Grathöhen, die Lochdurchmesserabweichungen und die Werkzeugverschleiße beim Bohren von Ti-6Al-4 V unter Trockenschneidbedingungen bei verschiedenen Schnittgeschwindigkeiten und Vorschubraten von Bohrern aus Woframcarbid (WC) und Hochgeschwindigkeitsschnellarbeitsstahl (HSS) untersucht. Darüber hinaus wurde eine mathematische Modellierung der Wirkkraft, der Oberflächenrauheit, der Grathöhen, der Lochdurchmesserabweichung und der Werkzeugverschleiße mittels Matlab durchgeführt. Es stellte sich heraus, dass die Vorschubrate, die Schnittgeschwindigkeit und der Bohrerwerkstoff erhebliche Auswirkungen auf die Wirkkraft, Oberflächenrauheit, Grathöhen, Lochdurchmesserabweichung und der Werkzeugverschleiße haben. Die besten Ergebnisse beim Bohren der Ti-6Al-4V-Legierung wurden mit dem WC-Bohrer erreicht.


*Correspondence Address, Assist. Prof. Dr. Yahya Hışman Çelik, Batman University, Department of Mechanical Engineering, 72100 Batman, Turkey. E-mail: ,

Yahya Hışman Çelik, born in 1980, received his BSc from the Mechanical Education Department, Faculty of Technical Education, University of Firat in Elazığ, Turkey, in 2002, his MSc and hid PhD from the Mechanical Department, Institute of Science and Technology, University of Firat, in 2005 and 2010. He is currently Assistant Professor at the University of Batman, Turkey, and his research areas concentrate on manufacturing, construction, molding and CAD/CAM as well as CNC.

Hakan Yildiz, received his BSc degree from Mechanical Engineering Department, Faculty of Engineering, Mustafa Kemal University, Antakya, Turkey, in 2010. He received his MSc degree from the Department of Mechanical Engineering of Batman University, Turkey, in 2015.

Cebeli Özek has been working as Associate Professor at Firat University, Elazığ, Turkey. His research interests include CNC, CAD-CAM, design and metal manufacturing processes. He also works with deep drawing dies and plastic injection molding.


References

1 M.Nouari, H.Makich: Experimental investigation on the effect of the material microstructure on tool wear when machining hard titanium alloys: Ti-6Al-4 V and Ti-555, International Journal of Refractory Metals and Hard Materials41 (2013), pp. 25926910.1016/j.ijrmhm.2013.04.011Search in Google Scholar

2 P. K.Farayibi, J. A.Folkes, A. T.Clare: Laser deposition of Ti-6Al-4 V wire with WC powder for functionally graded components, Materials and Manufacturing Processes28 (2013), pp. 51451810.1080/10426914.2012.718477Search in Google Scholar

3 N.Khanna, J. P.Davim: Design-of-experiments application in machining titanium alloy for aerospace structural components, Measurement61 (2015), pp. 28029010.1016/j.measurement.2014.10.059Search in Google Scholar

4 Y. H.Çelik: Investigating the effects of cutting parameters on the hole quality in drilling the Ti-6Al-4 V alloy, Materiali in Tehnologije48 (2014), No. 5, pp. 653659 UDK 621.95:669.295Search in Google Scholar

5 R.Komanduri, W. R.Reed: Evaluation of carbide grades and a new cutting geometry for machining titanium alloys, Wear92 (1983), pp. 11312310.1016/0043-1648(83)90011-XSearch in Google Scholar

6 J. R.Myers, H. B.Bomberger, F. H.Froes: Corrosion behaviour and use of titanium and its alloys, Journal of Metals36 (1984), No. 10, pp. 5060Search in Google Scholar

7 F. H.Froes, H. B.Bomberger: The beta titanium alloys, Journal of Metals36 (1985), No. 11, pp. 5562Search in Google Scholar

8 U.Çaydaş, A.Hasçalık, Ö.Buytoz, A.Meyveci: Performance evaluation of different twist drills in dry drilling of AISI 304 austenitic stainless steel, Materials and Manufacturing Processes20 (2011), pp. 95196010.1080/10426914.2010.520790Search in Google Scholar

9 K. H.Park, A.Beal, D.Kim, P.Know, J.Lantrip: Tool wear in drilling of composite/titanium stack using carbide and polycrystalline diamond tools, Wear271 (2011), pp. 2826283510.1016/j.wear.2011.05.038Search in Google Scholar

10 A.Yardimeden, E.Kilickap, Y. H.Celik: Effects of cutting parameters and point angle on thrust force and delamination in drilling of CFRP, Materials Testing56 (2014), No. 11–12, pp. 1042104810.3139/120.110666Search in Google Scholar

11 T.Minton, S.Ghani, F.Sammler, R.Bateman, P.Füstmann, M.Roeder: Temperature of internally-cooled diamond-coated tools for dry-cutting titanium, International Journal of Machine Tools and Manufacture75 (2013), pp. 273510.1016/j.ijmachtools.2013.08.006Search in Google Scholar

12 F.Wang, Y.Liu, Y.Zhang, Z.Tang, R.Ji, C.Zheng: Compound machining of titanium alloy by super high speed EDM milling and arc machining, Journal of Materials Processing Technology214 (2014), pp. 53153810.1016/j.jmatprotec.2013.10.015Search in Google Scholar

13 M.Sentilkumar, A.Parabukarthi, V.Krishnaraj: Study on tool wear and chip formation during drilling carbon fiber reinforced polymer (CFRP)/titanium alloy (Ti-6Al-4V) stacks, Procedia Engineering64 (2013), pp. 58259210.1016/j.proeng.2013.09.133Search in Google Scholar

14 E.Feldsthein: The influence of machining condition on burr shapes when drilling reach-through holes in difficult-to-cut materials, Advanced in Manufacturing Science and Technology35 (2011), No. 4, pp. 7583Search in Google Scholar

15 J. L.Cantero, M. M.Tardío, J. A.Canteli, M.Marcos, M. H.Miguélez: Dry drilling of alloy Ti-6Al-4V, International Journal of Machine Tools and Manufacture45 (2005), No. 11, pp. 1246125510.1016/j.ijmachtools.2005.01.010Search in Google Scholar

16 Ö.Isbilir, E.Ghassemieh: Finite element analysis of drilling of titanium alloy, Procedia Engineering10 (2011), pp. 1877188210.1016/j.proeng.2011.04.312Search in Google Scholar

17 Y. H.Guu, C. S.Deng, M.Ti-Kunang Hou, C. H.Hsu, K. S.Tseng: Optimization of machining parameters for stress concentration in microdrilling of titanium alloy, Materials and Manufacturing Processes27 (2012), pp. 20721310.1080/10426914.2011.566657Search in Google Scholar

18 D.Biermann, H.Hartmann: Reduction of burr formation in drilling using cryogenic process cooling, Proc. 3 of the 45th CIRP Conference on Manufacturing System (2012), pp. 859010.1016/j.procir.2012.07.016Search in Google Scholar

19 J.Pujana, A.Rivero, A.Celaya, L. N.López de Lacalle: Analysis of ultrasonic-assisted drilling of Ti-6Al-4V, International Journal of Machine Tools and Manufacture49 (2009), No. 6, pp. 50050810.1016/j.ijmachtools.2008.12.014Search in Google Scholar

20 O.Pecat, E.Brinksmeier: Tool wear analyses in low frequency vibration assisted drilling of CFRP/Ti-6Al-4 V stack materials, Proc. of CIRP14 (2014), pp. 14214710.1016/j.procir.2014.03.050Search in Google Scholar

21 O.Pecat, EBrinksmeier: Low damage drilling of CFRP/titanium compound materials for fastening, Procedia CIRP13 (2014), pp. 1710.1016/j.procir.2014.04.001Search in Google Scholar

22 P. K.Shetty, R.Shetty, D.Shetty, F.Rehaman, T. K.Jose: Machinability study on dry drilling of titanium alloy Ti-6Al-4 V using L9 orthogonal array, Procedia Materials Science5 (2014), pp. 2605261410.1016/j.mspro.2014.07.521Search in Google Scholar

23 J.Prasanna, L.Karunamoorthy, M. V.Raman, S.Prashanth, D. R.Chordia: Optimization of process parameters of small hole dry drilling in Ti-6Al-4 V using Taguchi and grey relational analysis, Measurement48 (2014), pp. 34635410.1016/j.measurement.2013.11.020Search in Google Scholar

24 G.Boothroyd, W. A.Knight: Fundamentals of Machining and Machine Tools, 3rd Edition, CRC Press, Boca Raton, Florida, USA (2005)Search in Google Scholar

25 L.Dan, J.Mathew: Tool wear and failure monitoring techniques for turning: A review, International Journal of Machine Tools and Manufacture30 (1990), No. 4, pp. 57959810.1016/0890-6955(90)90009-8Search in Google Scholar

26 P. F.Zhang, N. J.Churi, Z. J.Pei, C.Treadwell: Mechanical drilling processes for titanium alloys: A literature review, Machining Sciences and Technology12 (2008), pp. 41744410.1080/10910340802519379Search in Google Scholar

27 D. A.Dornfeld: Strategies for preventing and minimizing burr formation, Laboratory for Manufacturing Automation, Consortium on Deburring and Edge Finishing, University of California at Berkeley, USA (2004), escholarship.org/uc/item/2239m1nsSearch in Google Scholar

Published Online: 2016-05-23
Published in Print: 2016-06-01

© 2016, Carl Hanser Verlag, München

Downloaded on 3.12.2023 from https://www.degruyter.com/document/doi/10.3139/120.110886/html
Scroll to top button