N. Fang, Q. Wua
Andrew Orme
5 October 2009
• Ti-6Al-4V
• Inconel 718
• Same set-up
• Measure cutting forces
• Tool wear
• Machined surface integrity (aerospace)
• Tool life
• Economics
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• Normal, Thrust, Cutting Force
• Equations
Fc = Fs cos ( b - a)/[cos ( f + b - a)]
Ft = Fs sin ( b - a)/[cos ( f + b - a)]
• Good comparison
• Minimize variation
• High Strength to weight ratio
• Low thermal conductivity
• Heat
•Chip formation
• Cutting Forces
• Cutting Power
• Cutting Energy
• Material Removal Rate
• Tool geometry
•Small feed rates 0.075, 0.09, 0.105, 0.12mm/r
• Work material (tube) Ti–6Al–4V and Inconel 718
• Tube outer diameter 50mm
• Tube wall thickness 1.4mm for Ti–6Al–4V
1. 2mm for Inconel 718
• Tool insert TPG 432 (Kennametal Inc.)
• Tool material Cemented carbide (KC 8050) with
TiC/TiN/TiCN coating
• Tool working rake angle 5◦
• Tool edge radius 0.06mm (.002in)
• Cutting speed 58, 87, 116, 144, 174m/min
.05*π=.157m
174m/min *
1rev/.157m =
1107rpm.
• CNC Turning Lathe
• Finish Machining
• Five Cutting Speeds
• Four feed rates
• No cutting fluid or coolant
• Tool radius measured after each cycle
• Kistler Dynamometer
• Kistler Amplifier
• Data Acquisition System(Labview)
• 20 Cutting Tests for each material
• Most tests repeated 3 times
(a) Ti
(b) Inconel
(a)Ti
(b) Inconel
Force Ratio
• Determines
direction of
resultant force
•Cutting Force
Fc_Ti64=103.52Vc−0.155f0.784w
Fc_In718=103.81Vc−0.153f0.894w
• Thrust Force
Ft_Ti64=103.02Vc−0.257f0.127w
Ft_In718=103.41Vc−0.216f0.495w
• Resultant Force
RTi64=103.44Vc−0.202f0.483w
RIn718=103.80Vc−0.175f0.746w
•Force Ratio
Fc_Ti64/Ft_Ti64=100.508Vc0.101f0.657
Fc_In718/Ft_In718=100.394Vc0.0635f0.400
Increased cutting speed means lower cutting forces but
higher force ratio.
2. Increased feed rate means increased cutting forces and
increased force ratio.
3. Cutting force and thrust are higher for Inconel than for
Titanium.
4. As feed rate changes, thrust force varies more in
Inconel than Titanium.
1.
• Jet Engines
• Aerospace
• High strength to low weight ratio
• High Speed Machining?
Develop new tools
• Equations can be used to estimate cutting forces.