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n South African Journal of Industrial Engineering - Effect of milling strategy and tool geometry on machining cost when cutting titanium alloys

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Abstract

The growing demands on aerospace manufacturers to cut more difficult-to-machine materials at increasing material removal rates require that manufacturers enhance their machining capability. This requires 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 also make the alloy very challenging to machine. Complex aerospace geometries necessitate large material removal, and are therefore generally associated with high manufacturing costs. To investigate the effect of milling strategy and tool geometry on cutting performance, the new constant engagement milling strategy was firstly compared with a conventional approach. Thereafter, a component was milled with different cutting tool geometries. Cost savings of more than 40% were realised by using a constant engagement angle milling strategy. A reduction of 38% in machining time was achieved by using 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.

Die groeiende aanvraag vir vervaardigers in die lugvaartbedryf om moeilik-masjineerbare materiale te sny met toenemende materiaalverwyderingstempo's vereis van vervaardigers om hul masjinerings vermoëns te verbeter. Dit benodig 'n beter begrip van die impak wat frees strategie en snybeitel geometrie op sny prestasie het. Ti6Al4V is die algemeenste titaan allooi wat gebruik word in die lugvaartbedryf as gevolg van 'n unieke kombinasie van eienskappe. Hierdie eienskappe is ook verantwoordelik vir die moeilik-masjineerbaarheid van hierdie metaal. Komplekse lugvaart geometrieë vereis groot hoeveelhede materiaalverwydering, en is gewoonlik geassosieer met hoë vervaardigingskostes. Om die effek wat frees strategie en snybeitel geometrie op sny prestasie het, is die nuwe konstante blootstellingshoek frees strategie eerstens vergelyk met 'n tradisionele benadering. Daarna is 'n komponent gefrees met verskillende snybeitel geometrieë. Koste besparings van meer as 40% is bewerkstellig deur 'n konstante blootstellingshoek frees strategie te implementeer. 'n Vermindering van 38% in masjineringstyd was moontlik deur gebruik te maak van snybeitels met 'n snykrag verminderingsontwerp op die kant van die snybeitel wat help met die spaandervloei. Hierdie inkrementele verbeteringe het dit moontlik gemaak om die algehele vermoë van die snyproses te verbeter.

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/content/indeng/26/3/EJC181205
2015-11-01
2016-12-04
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