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Technical Brief

Evaluation of Performance of Various Coolant Grades When Turning Ti-6Al-4V Alloy With Uncoated Carbide Tools Under High-Pressure Coolant Supplies

[+] Author and Article Information
Emmanuel O. Ezugwu

Air Force Institute of Technology,
Kaduna 800282, Nigeria
e-mail: eoezugwu@googlemail.com

Rosemar B. da Silva

School of Mechanical Engineering,
Federal University of Uberlandia,
Uberlandia 38400-902, MG, Brazil
e-mail: rosemar.silva@ufu.br

John Bonney

Department of Mechanical Engineering,
Koforidua Polytechnic,
Koforidua 03420, Ghana
e-mail: john.bonney@koforiduapoly.edu.gh

Eder S. Costa

School of Mechanical Engineering,
Federal University of Uberlandia,
Uberlandia 38400-902, MG, Brazil
e-mail: edercosta@ufu.br

Wisley F. Sales

School of Mechanical Engineering,
Federal University of Uberlandia,
Uberlandia 38400-902, MG, Brazil
e-mail: wisley@ufu.br

Alisson R. Machado

School of Mechanical Engineering,
Federal University of Uberlandia,
Uberlandia 80215-901, MG, Brazil;
Mechanical Engineering Graduate Program,
Pontifícia Universidade Católica do Paraná—PUC-PR,
Curitiba CEP 80215-901, PR, Brazil
e-mail: alisson.rocha@pucpr.br

1Corresponding author.

Manuscript received January 26, 2018; final manuscript received September 20, 2018; published online November 8, 2018. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 141(1), 014503 (Nov 08, 2018) (9 pages) Paper No: MANU-18-1056; doi: 10.1115/1.4041778 History: Received January 26, 2018; Revised September 20, 2018

This work presents the evaluation of three commercially available coolant grades (dicyclohexylamine-based coolant, a triethanolamine-based coolant, and an ester-based coolant) when machining Ti-6Al-4V alloy with high-pressure coolant delivery. The evaluations were based on tool life, tool failure modes, surface integrity, and chip formation. The dicyclohexylamine-based coolant was the more effective coolant when machining at the highest pressure of 20.3 MPa due to its stability at elevated temperature, whereas the triethanolamine-based coolant performed effectively at a pressure of 11 MPa due to its low surface tension properties. Deterioration of the ester-based coolant was found in almost all coolant pressures due to its low resistance to oxidation. Surfaces generated when machining with all coolants grades were generally acceptable with negligible physical damage.

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Figures

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Fig. 1

Comparison of FTIR spectra at the peaks of 1740 cm−1 for all coolants investigated before and after machining: (a) coolant type A, (b) coolant type B, and (c) coolant type C

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Fig. 2

Setup for high-speed machining of Ti-6Al-4V alloy applied at high pressure and conventionally overhead: (a) conventional overhead coolant flow and (b) high-pressure directional coolant application

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Fig. 3

Tool life recorded when machining Ti-6Al-4V alloy with various coolant grades and at different cutting conditions

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Fig. 4

Typical chips generated when machining Ti-6Al-4V alloy at 110 m/min cutting speed under various coolant supply pressures

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Fig. 5

Comparison of coolant residue after machining with: (a) coolant type A, (b) coolant type B, and (c) coolant type C

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Fig. 6

Worn cutting edge of uncoated carbide inserts after machining Ti-6Al-4V alloy at 130 m/min cutting speed under a coolant pressure of 20.3 MPa with various coolants: (a) coolant type A, (b) coolant type B, and (c) coolant type C

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Fig. 7

Surface roughness variation recorded when machining Ti-6Al-4V alloy with all the coolant grades investigated and under various cutting conditions

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Fig. 8

Surface profile at 120 m/min, 11.0 MPa coolant pressure: (a) coolant type A, (b) coolant type B, and (c) coolant type C

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Fig. 9

Etched sections of machined surfaces perpendicular to the tool feed direction at 120 m/min cutting speed and 11.0 MPa coolant pressure: (a) coolant type A, (b) coolant type B, and (c) coolant type C

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