Research Papers

Correlation of the Volumetric Tool Wear Rate of Carbide Milling Inserts With the Material Removal Rate of Ti–6Al–4V

[+] Author and Article Information
Mathew Kuttolamadom

Manufacturing & Mechanical Engg. Technology,
Texas A&M University,
College Station, TX 77843
e-mail: mathew@tamu.edu

Parikshit Mehta

Dept. of Mechanical Engg.,
Clemson University,
Clemson, SC 29634
e-mail: pariksm@g.clemson.edu

Laine Mears

International Center for Automotive Research,
Clemson University,
Greenville, SC 29607
e-mail: mears@clemson.edu

Thomas Kurfess

Dept. of Mechanical Engg.,
Georgia Institute of Technology,
Atlanta, GA 30332
e-mail: kurfess@gatech.edu

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received February 28, 2014; final manuscript received January 9, 2015; published online February 16, 2015. Assoc. Editor: Patrick Kwon.

J. Manuf. Sci. Eng 137(2), 021021 (Apr 01, 2015) (8 pages) Paper No: MANU-14-1081; doi: 10.1115/1.4029649 History: Received February 28, 2014; Revised January 09, 2015; Online February 16, 2015

The objective of this paper is to assess the correlation of volumetric tool wear (VTW) and wear rate of carbide tools on the material removal rate (MRR) of titanium alloys. A previously developed methodology for assessing the worn tool material volume is utilized for quantifying the VTW of carbide tools when machining Ti–6Al–4V. To capture the tool response, controlled milling experiments are conducted at suitable corner points of the recommended feed-speed design space, for constant stock material removal volumes. For each case, the tool material volume worn away, as well as the corresponding volumetric wear profile evolution in terms of a set of geometric coefficients, is quantified—these are then related to the MRR. Further, the volumetric wear rate and the M-ratio (volume of stock removed to VTW) which is a measure of the cutting tool efficiency, are related to the MRR—these provide a tool-life based optimal MRR for profitability. This work not only elevates tool wear from a 1D to 3D concept, but helps in assessing machining economics from a stock material-removal-efficiency perspective as well.

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Fig. 1

An inconsistent wear quantification scenario

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Fig. 2

General VTW procedure for a new tool: (a) reference entities shown on tool, (b) point-cloud 3D model, (c) point-cloud in rectangular coordinates, (d) truncated surface model, (e) four bounding planes created off reference entities for cordoning tool body, and (f) 3D solid model of the volumetric region of interest

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Fig. 3

Volumetric wear vs. increasing feeds and speeds

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Fig. 4

The correlation of VTW with MRR

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Fig. 5

High feed–low speed resulting chatter marks visible on a turned Ti–6Al–4V workpiece

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Fig. 6

The correlation of specific VTW rate with MRR

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Fig. 7

Dependence of accumulated wear on VTW rate

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Fig. 11

The correlation of the M-ratio with MRR

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Fig. 8

Geometric coefficients defined on flank face plane for wear tracking: (a) intensity map and (b) 3D model

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Fig. 9

Geometric coefficient defined into the tool body for wear tracking: (a) 3D model and (b) surface profile

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Fig. 10

Evolution of the average of the set of geometric coefficients for each pass



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