Title: Analysis of the adhesion wear mechanism and brittle failure of carbide tools when dry machining the aeronautical titanium alloy: Ti-6Al-4V

Authors: Mohammed Nouari, Armansyah Ginting

Addresses: LEMTA CNRS-UMR 7563, Ecole Nationale Superieure des Mines de Nancy (ENSMN), GIP-InSIC, 27 rue d'Hellieule, 88100 Saint-Die-des-Vosges, France. ' Department of Mechanical Engineering, Faculty of Engineering, University of Sumatera Utara Jalan Almamater 20155 Medan, North Sumatera, Indonesia

Abstract: Titanium alloys are widely used for applications requiring high strength at elevated temperature and high mechanical resistance. The main problems encountered when machining this kind of materials are the low material removal rate and premature tool wear. In the current study, the usual titanium alloy Ti-6Al-4V is machined under orthogonal cutting configuration without using lubrication (dry machining). Three rake angles of 0°, 15° and 30°, three cutting speeds of 15, 30 and 60 m/min, and three feeds of 0.1, 0.2, and 0.3 mm were selected. The chip load (V.f) is used to calculate the flow localisation parameter β. The later is a good indication on the chip shape. It has been found that the serrated chip shape starts at β of 4.70 which corresponds to chip load V.f of 0.0045 m²/min. In this case, a brittle failure is produced by the formation of Built-Up-Layers (adhesion wear) at the tool-chip interface.

Keywords: dry machining; Ti-6Al-4V; adhesion wear; flow localisation; chip load; brittle failure; carbide tools; aeronautical titanium alloys; orthogonal cutting; tool-chip interface.

DOI: 10.1504/IJMSI.2008.019612

International Journal of Materials and Structural Integrity, 2008 Vol.1 No.4, pp.277 - 293

Published online: 17 Jul 2008 *

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