Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V
Ball-end cutters are widely used for machining the parts of Ti-6Al-4V, which have the problem of poor machined surface quality due to the low cutting speed near the tool tip. In this paper, through the experiments of inclined surface machining in different feed directions, it is found that the surfa...
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| Format: | Article |
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MDPI AG
2021-11-01
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| Online Access: | https://www.mdpi.com/1996-1944/14/23/7143 |
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| author | Anshan Zhang Caixu Yue Xianli Liu Steven Y. Liang |
| author_facet | Anshan Zhang Caixu Yue Xianli Liu Steven Y. Liang |
| author_sort | Anshan Zhang |
| collection | DOAJ |
| description | Ball-end cutters are widely used for machining the parts of Ti-6Al-4V, which have the problem of poor machined surface quality due to the low cutting speed near the tool tip. In this paper, through the experiments of inclined surface machining in different feed directions, it is found that the surface adhered damages will form on the machined surface under certain tool postures. It is determined that the formation of surface adhered damage is related to the material adhesion near the cutting edge and the cutting-into/out position within the tool per-rotation cycle. In order to analyze the cutting-into/out process more clearly under different tool postures, the projection models of the cutting edge and the cutter workpiece engagement on the contact plane are established; thus, the complex geometry problem of space is transformed into that of plane. Combined with the case of cutting-into/out, chip morphology, and surface morphology, the formation mechanism of surface adhered damage is analyzed. The analysis results show that the adhered damage can increase the height parameters <i>Sku</i>, <i>Sz</i>, <i>Sp</i>, and <i>Sv</i> of surface topographies. <i>Sz</i>, <i>Sp</i>, and <i>Sv</i> of the normal machined surface without damage (<i>Sku</i> ≈ 3) are about 4–6, 2–3, and 2–3 μm, while <i>Sz</i>, <i>Sp</i>, and <i>Sv</i> with adhered damage (<i>Sku</i> > 3) can reach about 8–20, 4–14, and 3–6 μm in down-milling and 10–25, 7–18, and 3–7 μm in up-milling. The feed direction should be selected along the upper left (<i>Q</i><sub>2</sub>: <i>β</i> ∈ [0°, 90°]) or lower left (<i>Q</i><sub>3</sub>: <i>β</i> ∈ [90°, 180°]) to avoid surface adhered damage in the down-milling process. For up-milling, the feed direction should be selected along the upper right (<i>Q</i><sub>1</sub>: <i>β</i> ∈ (−90°, 0°]) or upper left (<i>Q</i><sub>2</sub>: <i>β</i> ∈ [0°, 90°)). |
| first_indexed | 2024-03-10T04:50:03Z |
| format | Article |
| id | doaj.art-255eb6ef279b47b2b39d126df1b4f0df |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T04:50:03Z |
| publishDate | 2021-11-01 |
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| spelling | doaj.art-255eb6ef279b47b2b39d126df1b4f0df2023-11-23T02:38:55ZengMDPI AGMaterials1996-19442021-11-011423714310.3390/ma14237143Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4VAnshan Zhang0Caixu Yue1Xianli Liu2Steven Y. Liang3Key Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science&Technology, Harbin 150080, ChinaKey Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science&Technology, Harbin 150080, ChinaKey Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science&Technology, Harbin 150080, ChinaGeorgia Institute of Technology, George W. Woodruff School of Mechanical Engineering, Atlanta, GA 30332, USABall-end cutters are widely used for machining the parts of Ti-6Al-4V, which have the problem of poor machined surface quality due to the low cutting speed near the tool tip. In this paper, through the experiments of inclined surface machining in different feed directions, it is found that the surface adhered damages will form on the machined surface under certain tool postures. It is determined that the formation of surface adhered damage is related to the material adhesion near the cutting edge and the cutting-into/out position within the tool per-rotation cycle. In order to analyze the cutting-into/out process more clearly under different tool postures, the projection models of the cutting edge and the cutter workpiece engagement on the contact plane are established; thus, the complex geometry problem of space is transformed into that of plane. Combined with the case of cutting-into/out, chip morphology, and surface morphology, the formation mechanism of surface adhered damage is analyzed. The analysis results show that the adhered damage can increase the height parameters <i>Sku</i>, <i>Sz</i>, <i>Sp</i>, and <i>Sv</i> of surface topographies. <i>Sz</i>, <i>Sp</i>, and <i>Sv</i> of the normal machined surface without damage (<i>Sku</i> ≈ 3) are about 4–6, 2–3, and 2–3 μm, while <i>Sz</i>, <i>Sp</i>, and <i>Sv</i> with adhered damage (<i>Sku</i> > 3) can reach about 8–20, 4–14, and 3–6 μm in down-milling and 10–25, 7–18, and 3–7 μm in up-milling. The feed direction should be selected along the upper left (<i>Q</i><sub>2</sub>: <i>β</i> ∈ [0°, 90°]) or lower left (<i>Q</i><sub>3</sub>: <i>β</i> ∈ [90°, 180°]) to avoid surface adhered damage in the down-milling process. For up-milling, the feed direction should be selected along the upper right (<i>Q</i><sub>1</sub>: <i>β</i> ∈ (−90°, 0°]) or upper left (<i>Q</i><sub>2</sub>: <i>β</i> ∈ [0°, 90°)).https://www.mdpi.com/1996-1944/14/23/7143ball-end millingtitanium alloyssurface adhered damagetool material adhesioncutting into/outfeed direction selection |
| spellingShingle | Anshan Zhang Caixu Yue Xianli Liu Steven Y. Liang Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V Materials ball-end milling titanium alloys surface adhered damage tool material adhesion cutting into/out feed direction selection |
| title | Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V |
| title_full | Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V |
| title_fullStr | Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V |
| title_full_unstemmed | Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V |
| title_short | Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V |
| title_sort | study on the formation mechanism of surface adhered damage in ball end milling ti6al4v |
| topic | ball-end milling titanium alloys surface adhered damage tool material adhesion cutting into/out feed direction selection |
| url | https://www.mdpi.com/1996-1944/14/23/7143 |
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