Andrew Orme 5 October 2009 N. Fang, Q. Wua

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 F c = F s cos (  cos (  F t = F s sin (  cos ( 

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 F c_Ti64 = V c −0.155 f w F c_In718 = V c −0.153 f w Thrust Force F t_Ti64 = V c −0.257 f w F t_In718 = V c −0.216 f w Resultant Force R Ti64 = V c −0.202 f w R In718 = V c −0.175 f w Force Ratio F c_Ti64 /F t_Ti64 = V c f F c_In718 /F t_In718 = V c f 0.400

1. 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.

Jet Engines Aerospace High strength to low weight ratio High Speed Machining? Develop new tools Equations can be used to estimate cutting forces.