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Suppressing notch wear by changing the tool path in the side milling of a Ti-6Al-4 V alloy

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Abstract

Despite many advantages offered by titanium alloys compared to other conventional materials in the industry, several manufacturing challenges arise, and they are associated with titanium’s mechanical, thermal, and chemical properties. As a result of these characteristics, titanium alloys are low-machinability materials. Machining path strategies have proven their influence over surface finishing, machining forces, and tool life to reduce machinability-related problems. Most studies have shown the impact of the path strategies on frontal or end milling processes, and few are related to side (tangential) milling. Finally, based on the self-propelled rotary tool (SPRT) technique, which alters the cutting tool portion during machining, this work evaluates surface finishing behavior, machining forces, and tool life using two different tool path strategies (sinusoidal and linear) on the side milling of Ti-6Al-4 V alloy. The results show that the association between an adequate tool path strategy (sinusoidal) and the cutting parameters improves surface finishing (more than 130%), decreases cutting forces (about 20%), changes tool wear mechanisms, and increases tool life significantly (4–5 times) without productivity loss. Wear mechanisms that promote notch wear were suppressed, and uniform flank wear predominated. Consequently, the sinusoidal path has brought benefits to the cutting process. It is a technology that can have great interest and is easily applicable in the industry.

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Acknowledgements

We thank the SENAI Mogi Guaçu, the SENAI in São Paulo, and the Surface Phenomena Laboratory (Poli-USP) for their technical and equipment support.

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Authors and Affiliations

  1. Department of Manufacturing and Materials Engineering, School of Mechanical Engineering, University of Campinas – UNICAMP, 200 Mendeleyev St., Barão Geraldo, Campinas, São Paulo, 13083-860, Brazil

    Ricardo Henrique Inácio, Rodrigo Henriques Lopes da Silva & Amauri Hassui

  2. Department of Mechanical Engineering, Federal Technological University of Paraná, Campus Cornélio Procópio, Paraná, Brazil

    Rodrigo Henriques Lopes da Silva

  3. Department of Mechanical Engineering, Federal University of Ouro Preto, Campus Morro Do Cruzeiro, Ouro Preto, Minas Gerais, Brazil

    Igor Cézar Pereira

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  1. Ricardo Henrique Inácio
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  4. Amauri Hassui
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Ricardo Inácio, Rodrigo Lopes da Silva, and Amauri Hassui contributed to the study in the phases of the design of experiments, experimentation, writing, and analysis. Igor Pereira worked on the writing and analysis. All authors read and approved the final manuscript.

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Correspondence to Rodrigo Henriques Lopes da Silva.

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Inácio, R.H., da Silva, R.H.L., Pereira, I.C. et al. Suppressing notch wear by changing the tool path in the side milling of a Ti-6Al-4 V alloy. Int J Adv Manuf Technol 125, 453–463 (2023). https://doi.org/10.1007/s00170-022-10741-y

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