SUNConferences, RAPDASA 2014

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EFFECT OF MILLING STRATEGY AND TOOL GEOMETRY ON CUTTING PERFORMANCE OF TITANIUM ALLOYS
Pieter Conradie, Dimitri Dimitrov, Tiaan Oosthuizen, Mike Saxer

Last modified: 2014-11-05

Abstract


The growing demands on aerospace manufacturers to cut more difficult-to-machine materials require manufacturers to increase their machining capability. This involves a better understanding of the effects of milling strategies and tool geometries on cutting performance. Ti6Al4V is the most widely used titanium alloy in the aerospace industry due to its unique combination of properties. These properties are also responsible for making the alloy very challenging to machine. Therefore, its machining processes are generally associated with high manufacturing costs. The complex geometries of aerospace parts necessitate that a very large amount of the original material should be machined away. The continual demand to also increase the material removal rates in combination with the milling challenges of titanium alloys creates the need to improve the performance of the cutting process. Recent studies have shown that milling strategies and cutting geometries can have a significant effect on the resource efficiency and performance of the cutting process. These research experiments were divided into two phases. Firstly, the new constant engagement milling strategy was compared with a conventional approach. Thereafter, a component was milled with different cutting tool geometries. Cost savings of more than 40% was realised by using a constant engagement angle milling strategy. A reduction of 38% in machining time was achieved by utilizing tools with a land on the rake side of the cutting edge. These incremental improvements made it possible to enhance the overall performance of the cutting process.




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