Fundamental Investigation into Tool Wear and Surface Quality in High-Speed Machining of Ti6Al4V Alloy

Evaluation of crude watermelon oil as lubricant in cylindrical turning of AISI 1525 steel employing Taguchi and grey relational analyses techniques

Cutting fluids are used for cooling and lubricating the machining area of components used in manufacturing industries such as aerospace, automotive, petroleum, and heavy machinery. Mineral oils derived from petroleum are commonly utilized as cutting fluids. Mineral oil is hazardous to the health of workers and damaging to the environment. There is a need for a substitute for mineral oil. Vegetable oil is increasingly being used as a cutting fluid. Vegetable oils are easily accessible and have benefits including excellent biodegradability, resistance to fire, low humidity rates, and a low coefficient of expansion under heat. This study adopts watermelon oil as a lubricant in MQL machining of AISI 1525 steel using tungsten tools. In the experiment, the feed rate, depth of cut (DC) and spindle speed were varied using the Taguchi L9 orthogonal array. Grey relational analysis was conducted to obtain optimum cutting parameters for surface roughness, machine vibration, and cutting temperature. Hardness and microstructural analysis of the workpiece were also conducted. Results showed that vegetable oil performed much more effectively than mineral oil in most experiments. The DC was shown to be the most efficient cutting parameter after applying ANOVA analysis based on the parameters that were evaluated. Additionally, models for cutting temperature, machine vibration, and surface roughness values have been developed with accuracy between 69.73 % and 99.05 %. The hardness of the workpiece increases with an increase in diameter, which was attributed to the increase in the steel rod (workpiece) cross-sectional area and the likelihood of a more uniform stress distribution. Moreover, finer grain sizes were observed at 70 mm diameter, with the predominant presence of pearlites. These characteristics were reportedly beneficial to the material's toughness and strength.

Subroutine Embedding and Finite Element Simulation of the Improved Constitutive Equation for Ti6Al4V during High-Speed Machining

The Johnson-Cook (J-C) constitutive model is not suitable for Ti-6Al-4V alloy in the high-speed cutting finite element simulation, as it has no response dynamic recrystallization softening effect under heavy impact and high temperature. In this paper, an improved constitutive model considering the recrystallization effect was established, and the parameters were fitted with the data of flow stress-strain of the Split Hopkinson Pressure Bar (SHPB) test. The relevant theories of cutting finite element simulation were studied, such as nonlinear constitutive elastic-plastic deformation, strain state, and material yield. A subroutine that included the Recht shear failure instability criterion and the improved model was coded in Fortran and embedded in the finite element simulation software AdvantEdge FEM, along with the return mapping stress integration algorithm. The simulated stress of the improved model dropped dramatically from 460 MPa to 220 MPa when the temperature rises from 950 °C to 1000 °C, and its decline reached 46.7%, while the J-C model only decreased by 10%. Comparative studies indicate that the stress change of the improved constitutive simulation is closer to the SHPB test results than the J-C constitutive, and the new one is more suitable when it expresses the high temperature and heavy impact in the high-speed milling.

Study on Characteristics for Reaming Titanium Alloy Ti6Al4V with Two Kinds of Cemented-Carbide Groove Reamers

Titanium alloys have been extensively used in practical machining owing to their outstanding mechanical properties, high specific strength and low thermal deformation. In this study, the cutting experiments are carried out on Ti6Al4V material with right-hand and straight cemented-carbide groove reamers. The experimental results show that the cutting force with the right-hand reamer is smaller compared to straight groove reamer due to the groove structure. The main tool wear forms are micro-chipping, adhesive wear, abrasive wear, and coating falling off on the right-hand reamer, while there is a built-up edge and serious damage failure on the cutting edge of the straight groove reamer. Notch wear and pitting on the surface of the hole wall are mainly caused by chip adhesion and tool wear. The surface-roughness value is the lowest as the cutting speed is 60 m/min and the feed rate is 0.4 mm/rev. The holes machined by the right-hand reamer have a low hole diameter deviation with various cutting parameters. The geometric accuracy of cylindricity is higher as the feed rate is 0.4 mm/rev and the cutting speed is 40 m/min for both kinds of reamers, and the cylindricity is better with the right-hand reamer.

Studies on Wear of a Milling Chuck for a Production Line of Specialized Elements Used in Lockstitch Machines

The study aims to determine the wear intensity of selected milling chuck assembly surfaces covered with a protective DLC (Diamond Like Carbon) coating, used on the production line for elements of selected lockstitch machines, and to analyze the stress distributions in the object fixed with such a chuck for the characteristic load systems of this object during its processing. A model of the workpiece was developed using the finite element method. The boundary conditions, including the load and the method of clamping the workpiece, resulted from the parameters of the milling process and the geometric configuration of the milling chuck. Stress distributions in the workpiece for specific milling parameters and for various configurations of the milling chuck holding the workpiece are included in the article. The model experimental studies of wear were conducted in the contact zone between two surfaces covered with DLC: one on the element of the milling chuck pressing the workpiece and the other on the eccentric cams of this holder. The obtained wear values and shapes for the worn surfaces are also shown. The wear intensities for the steel plunger fins modelling swivel arm of the holder were by an order higher than those of corresponding steel shaft shoulders modelling eccentric cam of the holder. The linear wear intensities for these mating components may be expressed in terms of a function of average contact pressure and sliding speed in a corresponding contact zone. The indentation of eccentric cam into mating surface of the swivel arm of the holder increased nonlinearly with the enhancement of number of cycles of the eccentric cam.

A comprehensive review on metallic implant biomaterials and their subtractive manufacturing

There is a tremendous increase in the demand for converting biomaterials into high-quality industrially manufactured human body parts, also known as medical implants. Drug delivery systems, bone plates, screws, cranial, and dental devices are the popular examples of these implants - the potential alternatives for human life survival. However, the processing techniques of an engineered implant largely determine its preciseness, surface characteristics, and interactive ability with the adjacent tissue(s) in a particular biological environment. Moreover, the high cost-effective manufacturing of an implant under tight tolerances remains a challenge. In this regard, several subtractive or additive manufacturing techniques are employed to manufacture patient-specific implants, depending primarily on the required biocompatibility, bioactivity, surface integrity, and fatigue strength. The present paper reviews numerous non-degradable and degradable metallic implant biomaterials such as stainless steel (SS), titanium (Ti)-based, cobalt (Co)-based, nickel-titanium (NiTi), and magnesium (Mg)-based alloys, followed by their processing via traditional turning, drilling, and milling including the high-speed multi-axis CNC machining, and non-traditional  abrasive water jet machining (AWJM), laser beam machining (LBM), ultrasonic machining (USM), and electric discharge machining (EDM) types of subtractive manufacturing techniques. However, the review further funnels down its primary focus on Mg, NiTi, and Ti-based alloys on the basis of the increasing trend of their implant applications in the last decade due to some of their outstanding properties. In the recent years, the incorporation of cryogenic coolant-assisted traditional subtraction of biomaterials has gained researchers' attention due to its sustainability, environment-friendly nature, performance, and superior biocompatible and functional outcomes fitting for medical applications. However, some of the latest studies reported that the medical implant manufacturing requirements could be more remarkably met using the non-traditional subtractive manufacturing approaches. Altogether, cryogenic  machining among the traditional routes and EDM among the non-traditional means along with their variants, were identified as some of the most effective subtractive manufacturing techniques for achieving the dimensionally accurate and biocompatible metallic medical implants with significantly modified surfaces.