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Research Papers

Cryogenic Machining of Titanium Ti-5553 Alloy

[+] Author and Article Information
Yusuf Kaynak

Mem. ASME
Department of Mechanical Engineering,
Technology Faculty,
Marmara University,
Goztepe Campus, Kadikoy,
34722 Istanbul, Turkey
e-mail: yusuf.kaynak@marmara.edu.tr, yusuf_kaynak@yahoo.com

Armin Gharibi

Department of Mechanical Engineering,
Institute of Pure and Applied Sciences,
Marmara University,
Goztepe Campus, Kadikoy,
34722 Istanbul, Turkey
e-mail: armin.gharibi@gmail.com

1Corresponding author.

Manuscript received June 26, 2018; final manuscript received January 1, 2019; published online February 28, 2019. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 141(4), 041012 (Feb 28, 2019) (9 pages) Paper No: MANU-18-1488; doi: 10.1115/1.4042605 History: Received June 26, 2018; Accepted January 02, 2019

Titanium alloy Ti-5Al-5V-3Cr-0.5Fe (Ti-5553) is a new generation of near-beta titanium alloy that is commonly used in the aerospace industry. Machining is one of the manufacturing methods to produce parts that are made of this near-beta alloy. This study presents the machining performance of new generation near-beta alloys, namely, Ti-5553, by focusing on a high-speed cutting process under cryogenic cooling conditions and dry machining. The machining experiments were conducted under a wide range of cutting speeds, including high speeds that used liquid nitrogen (LN2) and carbon dioxide (CO2) as cryogenic coolants. The experimental data on the cutting temperature, tool wear, force components, chip breakability, dimensional accuracy, and surface integrity characteristics are presented and were analyzed to evaluate the machining process of this alloy and resulting surface characteristics. This study shows that cryogenic machining improved the machining performance of the Ti-5553 alloy by substantially reducing the tool wear, cutting temperature, and dimensional deviation of the machined parts. The cryogenic machining also produced shorter chips as compared to dry machining.

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Figures

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Fig. 1

Experimental setup for cryogenic machining application

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Fig. 2

Example of measured temperature profile

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Fig. 3

Measured maximum temperature during machining under dry, LN2, and CO2 conditions

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Fig. 4

Measured maximum flank wear under dry, LN2, and CO2 conditions

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Fig. 5

Tool–chip contact area resulting from dry, LN2, and CO2 machining conditions

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Fig. 6

Cross section of cutting tools used under dry, LN2, and CO2 conditions at 210 m/min and comparison with fresh tool

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Fig. 7

3D images of cutting tools used in various conditions at 210 m/min cutting speed

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Fig. 8

Temperature versus hardness relationship for tungsten carbide cutting tool, adapted from Ref. [38]

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Fig. 9

The main cutting force under dry, LN2, and CO2 machining conditions at varying cutting speeds

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Fig. 10

The feed force under dry, LN2, and CO2 machining conditions at varying cutting speeds

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Fig. 11

The radial force under dry, LN2, and CO2 machining conditions at varying cutting speeds

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Fig. 12

The effects of strain rate and temperature on deformation response of the Ti-5553 alloy adapted from Ref. [39]

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Fig. 13

Specific cutting forces and material removal rate under dry, LN2, and CO2 machining conditions at varying cutting speeds

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Fig. 14

Generated chips under dry, LN2, and CO2 machining conditions at varying cutting speeds

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Fig. 15

Average chip thickness as a function of cutting speed for dry, LN2, and CO2 machining conditions

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Fig. 16

Dimensional deviation of workpiece produced resulting from dry, LN2, and CO2 machining conditions

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Fig. 17

The effects of various machining conditions on surface and subsurface microhardness of machined parts at 120 m/min

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Fig. 18

XRD analysis of parts machined under dry, LN2, and CO2 conditions at 120 m/min cutting speed

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