Search Results (3)

The titanium alloy Ti-6Al-4V ELI is most commonly used for medical implant products because it is corrosion resistant, high strength, and lightweight. In actuality, the temperature will be very high during the machining of this material. This will accelerate the tool wear and affect the surface roughness. Turning with the actively driven rotary tool (ADRT) has been proven to decrease the cutting temperature so that it is suitable for machining the Ti-6Al-4V ELI. This study focuses on investigating the surface roughness and morphology of Ti-6Al-4V ELI when turning with the ADRT. The surface roughness was measured using the surface profile tester, while the surface morphology was observed using a Scanning Electron Microscope (SEM). The turning with ADRT parameters consisting of the tool diameter, cutting speed, tool revolution speed, feed, and tool inclination angle were analyzed for their effects on the surface roughness. Results show that the cutting speed and tool inclination angle have a significant effect, with a contribution effect of about 67% on the average surface roughness (R_a). The increasing cutting speed resulted in the increased average surface roughness (R_a). The average surface roughness (R_a) also increased with an increasing tool inclination angle. Moreover, no physical damage was observed, such as cracks, micro-pits, and a white layer on the material’s surface morphology. Full article

Machining with rotating tools appears to be an efficient method that employs a non-standard kinematic turning scheme. It is used in the machining of materials that we classify in the category of difficult to machine. The titanium alloy Ti-6Al-4V, which is widely used in industry and transportation, is an example of such material. Rotary tool machining of titanium alloys has not been the subject of many studies. Additionally, if researchers were dissatisfied with their findings, the reason may not be the kinematic machining scheme itself but rather the tool design and the choice of cutting parameters. When tools are constructed of several components, inaccuracies in production and assembly can arise, resulting in deviations in the cutting part area. A monolithic driven rotary tool eliminates these factors. In the machining process, however, it may react differently from multi-component tools. The presented work focuses on the research of the technology for machining titanium alloy Ti-6Al-4V using a monolithic driven rotary tool. The primary goal is to gather data on the impact of cutting parameters on the machining process. The cutting force and the consequent integrity of the workpiece surface are used to monitor the process. The speed of workpiece rotation has the greatest impact on the process; as it increases, the cutting force increases, as do the values of the surface roughness. In the experiment, lower surface roughness values were attained by increasing the feed parameter and the depth of cut. This may predetermine the inclusion of a kinematic scheme in highly productive technologies. Full article

Forced rotation turning appears to be an effective machining method due to higher tool life, time efficiency and acceptable quality. Several studies have been carried out to investigate the basic characteristics of forced rotation machining. So far, tools are used whose design included several components. However, such tools may generate vibrations, which are undesirable in the process. In engineering practice, most vibration problems are solved by reducing the cutting parameters (cutting speed and feed rate), which reduces machining productivity. For this reason, a new type of monolithic rotary tool has been designed that eliminates the design complexity and high assembly accuracy requirements of current rotary tools. Based on the performed experimental research, it is possible to define the influence of cutting parameters on the cutting force. Next, the equation of the cutting force and the resulting roughness of the machined surface was determined. In the introduction, the results of the analysis of machining parameters with a rotary tool were added. The presented solution fundamentally validates the new monolithic tool for forced rotation technology and defines its application for different machining materials. Full article