在不同切削液策略下使用微柱状纹理刀具加工添加制造的 Ti6Al4V 的可加工性分析

IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL
Wear Pub Date : 2024-07-31 DOI:10.1016/j.wear.2024.205514
Gaurav Saraf, Sharib Imam, Chandrakant K. Nirala
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引用次数: 0

摘要

快速成型技术可将钛合金部件直接制成近净形状,从而减少了机加工的需要。然而,为了立即调整设计、改变尺寸和提高表面质量,需要进行添加制造后加工。增材制造过程中固有的热效应会改变机械性能,包括增加强度和硬度,但降低延展性,因此机械加工具有挑战性。纹理切削工具被广泛用于提高超合金的可加工性。在这项工作中,使用反向微放电加工(RμEDM)在硬质合金刀片上创建微柱状纹理,旨在探索选择性激光熔化(SLM)钛合金车削加工的可加工性。该研究调查了在各种切削液策略下,微柱与 SLM Ti6Al4V 在切屑行为、刀具形态、切削力和表面粗糙度方面的相互作用。在最小量润滑(MQL)条件下,纹理刀具表现出显著的改进,可产生卷曲半径减小的无缠结切屑。刀具/切屑接触面积大幅减少了 38%,这表明夹持区大幅缩小,从而降低了切削刀具的温升。在干燥条件下,侧面磨损宽度减少了 20.4%,这表明刀具纹理可延长切削刃的锋利度。在 MQL 条件下,进给力最大降低了 28.9%,表明界面摩擦条件得到改善。此外,表面光洁度也提高了 10.4%。这项工作的总结是,微柱状纹理刀具通过改善钛的附着力、切削刃锋利度、进给力和表面光洁度,特别是在 MQL 条件下,提高了添加制造的 Ti6Al4V 的可加工性。
本文章由计算机程序翻译,如有差异,请以英文原文为准。

Machinability analysis of additively manufactured Ti6Al4V using micro-pillar textured tool under various cutting fluid strategies

Machinability analysis of additively manufactured Ti6Al4V using micro-pillar textured tool under various cutting fluid strategies

Additive manufacturing makes fabricating titanium alloy components directly into their near-net shapes possible, reducing the need for machining. However, post-additive manufacturing machining becomes necessary for immediate design adjustments, dimension alterations, and surface quality enhancement. The inherent thermal effects during additive manufacturing make machining challenging due to altered mechanical properties from their wrought counterpart, including increased strength and hardness with reduced ductility. Textured cutting tools are being widely used to enhance the machinability of superalloys. In this work, micro-pillar type textures, created using Reverse Micro Electrical Discharge Machining (RμEDM) on tungsten carbide inserts, aimed to explore machinability in turning operations on selective laser melted (SLM) titanium alloy. The study investigates micro-pillar interaction with SLM Ti6Al4V in chip behavior, tool morphology, cutting forces, and surface roughness under various cutting fluid strategies. Under Minimum Quantity Lubrication (MQL), textured tools show significant improvements, producing untangled chips with reduced curl radius. A considerable decrease of 38 % in the tool/chip contact area indicates a substantial reduction in the seizure zone, hence a decline in the temperature rise of the cutting tool. Dry conditions show a 20.4 % reduction in flank wear width, suggesting prolonged cutting-edge sharpness due to tool texturing. In MQL conditions, a maximum 28.9 % reduction in feed force is observed, indicating improved frictional conditions at the interface. Additionally, a 10.4 % improvement in surface finish is achieved. The work is summarized by claiming micro-pillar textured tools enhance the machinability of additively manufactured Ti6Al4V demonstrated through improvements in titanium adhesion, cutting-edge sharpness, feed force, and surface finish, particularly MQL conditions.

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来源期刊
Wear
Wear 工程技术-材料科学:综合
CiteScore
8.80
自引率
8.00%
发文量
280
审稿时长
47 days
期刊介绍: Wear journal is dedicated to the advancement of basic and applied knowledge concerning the nature of wear of materials. Broadly, topics of interest range from development of fundamental understanding of the mechanisms of wear to innovative solutions to practical engineering problems. Authors of experimental studies are expected to comment on the repeatability of the data, and whenever possible, conduct multiple measurements under similar testing conditions. Further, Wear embraces the highest standards of professional ethics, and the detection of matching content, either in written or graphical form, from other publications by the current authors or by others, may result in rejection.
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