Comparative study of performance difference geometries carbide tool in turning titanium alloy TI-6AL-4V ELI

Abdul Mua’in, Mohammad Haziq Hilmi (2024) Comparative study of performance difference geometries carbide tool in turning titanium alloy TI-6AL-4V ELI. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

Since titanium alloy Ti-6Al-4V ELI has a good strength to weight ratio, it is utilised extensively. In metal cutting, one of the important elements which must seriously consider is geometries of cutting tools. Carbide cutting tool is widely used in machining process for various metal types with suitable geometries carbide. This paper presents the mechanism of tool failure, the wear pattern and tool life of the CNC turning Ti-6Al-4V ELI by comparing it to three type of carbide tool geometry: rhombic 80˚, rhombic 35˚, and trigon 80˚. The combination of parameter is arranged such as cutting speed with range of 90 to 150 m/min, feed rate with 0.1 to 0.2 mm/rev, and depth of cut was kept constant at 0.4 mm. A three-axis microscope was used to measure the flank wear for every 20 mm on the workpiece with 5 value of flank wear for each combination parameter for three type of carbide tool geometry. From the result obtained, it is found that the rhombic 80˚ resulted in longer tool life and show that the lowest cutting speed and feed rate resulted in longer tool life. The optimal feed rate was 0.2 mm/rev, with which a tolerable tool life was obtained for three difference geometry. Based on the result, the rhombic 35˚ carbide tool caused the highest wear rate. The optimum responses are obtained at cutting speed 120 m/min cutting speed with 0.2 mm/rev feed rate that obtained for 80˚ rhombic insert. By linking the machine operations and the tool life curves obtained using flank wear data, the wear behaviour of geometry carbide tool for uncoated carbide was described. From this research, even though titanium alloy, Ti-6Al-4V ELI is considered as material with low machinability, there are suitable geometry carbide available to give out the longest tool life thus reducing machining cost.

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