Thermal assessment and energy analysis in the machining of titanium alloys using SPRT.

Abstract

Understanding the interplay between tool dynamics and thermal behaviour is essential when machining challenging materials like titanium alloys. Ti54M, a titanium alloy with low thermal conductivity, poses significant machining challenges due to heat concentration in the secondary cutting zone (SCZ). Excessive heat in this zone accelerates tool wear, reducing efficiency and surface quality. Self-Propelled Rotary Tools (SPRTs) address these issues by introducing passive rotation of the cutting insert, redistributing heat and wear across the tool surface. This study investigates the relationships between tool rotation speed, chip flow velocity, and their indirect effects on thermal behaviour, addressing gaps noted in foundational studies. Using high-speed cameras, experiments analysed the kinematic interactions under various cutting conditions. Results demonstrate that higher chip flow velocities and tool rotation speeds enhance heat evacuation, mitigating localized thermal peaks. Unlike prior works, this study emphasizes indirect thermal indicators, contributing unique insights to SPRT technology. These findings provide a comprehensive understanding of the interplay between kinematics and thermal effects, offering practical guidelines for optimizing machining parameters. Future research will integrate advanced thermal imaging techniques to validate these findings and explore their broader implications for sustainable machining.