Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V
This article presents the results of an experimental investigation into the effect of process parameters in the precision hard turning of Ti-6Al-4V on chip morphology at both macro and micro levels. It also reports on the control of chip generation to improve chip evacuation and breakability at the...
| Main Authors: | , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-10-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/14/10/1973 |
| _version_ | 1827720408320704512 |
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| author | Elshaimaa Abdelnasser Samar El-Sanabary Ahmed Nassef Azza Barakat Ahmed Elkaseer |
| author_facet | Elshaimaa Abdelnasser Samar El-Sanabary Ahmed Nassef Azza Barakat Ahmed Elkaseer |
| author_sort | Elshaimaa Abdelnasser |
| collection | DOAJ |
| description | This article presents the results of an experimental investigation into the effect of process parameters in the precision hard turning of Ti-6Al-4V on chip morphology at both macro and micro levels. It also reports on the control of chip generation to improve chip evacuation and breakability at the macro level by varying the process parameters, namely, feed rate, cutting speed and depth of cut during turning tests. A scanning electron microscope (SEM) was used to examine the chips produced for a better understanding of chip curling mechanisms at the micro level. Surface roughness of the machined specimens was measured to assess the effect of chip evacuation on obtainable surface quality. From the results, it was found that the interaction of process parameters has a significant effect on the control of chip formation. In particular, the interaction of higher cutting speeds and greater depths of cut produced chip entanglement with the workpiece for all values of feed rates. Using relatively higher feed rates with a low depth of cut showed good results for chip breaking when machining at higher cutting speeds. Different chip curling mechanisms were identified from the SEM results. Chip side-curl formation showed different segmentation patterns with an approximately uniform chip thickness along the chip width, while chip up-curl occurred due to variations in chip thickness. Finally, it was found that the tangling of the chip with the workpiece has a significant effect on the final surface quality. |
| first_indexed | 2024-03-10T21:02:51Z |
| format | Article |
| id | doaj.art-abbfa0f40fa246e593641aebc9efea62 |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-03-10T21:02:51Z |
| publishDate | 2023-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-abbfa0f40fa246e593641aebc9efea622023-11-19T17:25:36ZengMDPI AGMicromachines2072-666X2023-10-011410197310.3390/mi14101973Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4VElshaimaa Abdelnasser0Samar El-Sanabary1Ahmed Nassef2Azza Barakat3Ahmed Elkaseer4Department of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Fouad 42526, EgyptDepartment of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Fouad 42526, EgyptDepartment of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Fouad 42526, EgyptMechanical Engineering Department, Faculty of Engineering, Helwan, Helwan University, Cairo 11792, EgyptDepartment of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Fouad 42526, EgyptThis article presents the results of an experimental investigation into the effect of process parameters in the precision hard turning of Ti-6Al-4V on chip morphology at both macro and micro levels. It also reports on the control of chip generation to improve chip evacuation and breakability at the macro level by varying the process parameters, namely, feed rate, cutting speed and depth of cut during turning tests. A scanning electron microscope (SEM) was used to examine the chips produced for a better understanding of chip curling mechanisms at the micro level. Surface roughness of the machined specimens was measured to assess the effect of chip evacuation on obtainable surface quality. From the results, it was found that the interaction of process parameters has a significant effect on the control of chip formation. In particular, the interaction of higher cutting speeds and greater depths of cut produced chip entanglement with the workpiece for all values of feed rates. Using relatively higher feed rates with a low depth of cut showed good results for chip breaking when machining at higher cutting speeds. Different chip curling mechanisms were identified from the SEM results. Chip side-curl formation showed different segmentation patterns with an approximately uniform chip thickness along the chip width, while chip up-curl occurred due to variations in chip thickness. Finally, it was found that the tangling of the chip with the workpiece has a significant effect on the final surface quality.https://www.mdpi.com/2072-666X/14/10/1973precision hard turningTi-6Al-4Vchip evacuation controlchip morphologyprocess parameterssurface roughness |
| spellingShingle | Elshaimaa Abdelnasser Samar El-Sanabary Ahmed Nassef Azza Barakat Ahmed Elkaseer Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V Micromachines precision hard turning Ti-6Al-4V chip evacuation control chip morphology process parameters surface roughness |
| title | Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V |
| title_full | Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V |
| title_fullStr | Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V |
| title_full_unstemmed | Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V |
| title_short | Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V |
| title_sort | influence of technological parameters on chip formation and chip control in precision hard turning of ti 6al 4v |
| topic | precision hard turning Ti-6Al-4V chip evacuation control chip morphology process parameters surface roughness |
| url | https://www.mdpi.com/2072-666X/14/10/1973 |
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