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Modeling of process forces with respect to technology parameters and tool wear in milling Ti6Al4V

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Abstract

The usage and importance of titanium materials is increasing worldwide. Titanium is particularly suitable for use in turbines and lightweight construction due to its high heat resistance and low density. However, its low thermal conductivity results in machining problems and short tool life due to the associated high mechanical and thermal tool loads. Knowledge about the mechanical tool load during the milling process is of vital importance to process design and modeling. This paper presents multivariate regression method to model the process forces involved in the titanium milling process with respect to various technology parameters. In particular, the resulting tool wear and its relationships with these process forces is analyzed.

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Abbreviations

A:

Cross section of undeformed chip (mm²)

ae :

Width of cut (mm)

ap :

Depth of cut (mm)

Fc :

Cutting force (N)

FcN :

Normal cutting force (N)

Fx :

Force in x-direction (N)

Fy :

Force in y-direction (N)

fz :

Feed per tooth (mm)

h:

Undeformed chip thickness (mm)

K:

Intercept

Kae:

Regression coefficient

Kap:

Regression coefficient

Kfz:

Regression coefficient

Kvc:

Regression coefficient

KVB:

Regression coefficient

KA:

Regression coefficient

V:

Material removal (cm3)

VB:

Width of flank wear land VB (µm)

vc :

Cutting speed (m/min)

φ:

Entry angle (°)

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Acknowledgements

This research and development project is funded by the German Federal Ministry of Education and Research (BMBF) within the 02PN2205 and managed by the Project Management Agency Karlsruhe (PTKA). The authors are responsible for the contents of this publication. The authors are also grateful to the anonymous reviewers for their constructive criticisms which served to improve the paper.

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  1. Institute of Production Management, Technology and Machine Tools, Otto-Berndt-Str. 2, 64287, Darmstadt, Germany

    E. Abele, C. Hasenfratz & M. Bücker

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  1. E. Abele
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  2. C. Hasenfratz
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  3. M. Bücker
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Correspondence to C. Hasenfratz.

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Abele, E., Hasenfratz, C. & Bücker, M. Modeling of process forces with respect to technology parameters and tool wear in milling Ti6Al4V. Prod. Eng. Res. Devel. 11, 285–294 (2017). https://doi.org/10.1007/s11740-017-0739-2

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  • DOI: https://doi.org/10.1007/s11740-017-0739-2

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