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Enhancement of machinability by workpiece preheating in end milling of Ti-6Al-4V

Hossain, Muhammad Ishtiyaq and Amin, A. K. M. Nurul and Patwari, Muhammed Anayet Ullah and Karim, A. (2008) Enhancement of machinability by workpiece preheating in end milling of Ti-6Al-4V. Journal of Achievements in Materials and Manufacturing Engineering, 31 (2). pp. 320-326. ISSN 1734-8412

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Purpose: The main objective of this paper is to investigate the effect of workpiece preheating with high frequency induction heating on improvement of machinability of Ti-6Al-4V during end milling using PVD TiAlN coated inserts. Tool life, cutting force and vibration were investigated during the experiments. Design/methodology/approach: End milling tests were conducted on Vertical Machining Centre (VMC ZPS, Model: MCFV 1060 with quarter immersion cutting. Titanium based alloy Ti-6Al-4V bar was used as the work-piece. Machining was performed with a 20 mm diameter end-mill tool holder (R390-020B20-11M) fitted with one insert. PVD TiAlN coated carbide inserts (R390-11 T3 08E-ML 2030) were used in the experiments. All of the experiments were run at room temperature and preheated conditions. The preheated temperature was maintained at 420ºC and no phase change of the workpiece in preheating was ensured from the phase diagram of Ti-6Al-4V. High frequency induction heating was utilized to run the preheated machining. Findings: Preheating helps in substantially increasing tool life and in lowering down the cutting force value, lowering the amplitude of vibration and dynamic forces. Practical implications: The cost of machining Ti-6Al-4V is extremely high because of the relatively low machining speed and short tool life. Therefore, improving the machinability of Ti-6Al-4V is a research topic of much interest, with a number of approaches reported with varied results, such as, cryogenic cutting, highpressure coolant, rotary-tool, and minimum quantity lubrication (MQL). Originality/value: A new approach of induction preheating to overcome the difficulties in machining of Ti-6Al-4V is presented in this paper. In preheated machining, high frequency induction heating is used as an external heat source to soften the work material surface layer in order to decrease its tensile strength and strain hardening. An experimental study has been performed to assess the effect of workpiece preheating using induction heating system to enhance the machinability of Ti-6Al-4V. The preheating temperature was maintained below the phase change temperature of Ti-6Al-4V.

Item Type: Article (Journal)
Uncontrolled Keywords: Hot machining; Induction heating; Ti-6Al-4V; End-milling; Tool life, Vibration/chatter; Cutting forces
Subjects: T Technology > TJ Mechanical engineering and machinery
T Technology > TS Manufactures
Kulliyyahs/Centres/Divisions/Institutes (Can select more than one option. Press CONTROL button): Kulliyyah of Engineering > Department of Manufacturing and Materials Engineering
Depositing User: Dr. A.K.M. Nurul Amin
Date Deposited: 26 Jan 2012 10:39
Last Modified: 30 Jun 2016 14:18
URI: http://irep.iium.edu.my/id/eprint/16557

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